yep it's a engineering design flaw, the coil over plugs suck, the original problem was not enough threads tapped into aluminum housing. the issue was fixed I think in 05 or maybe 06.
there are several issues that ford could have done to improve the 5.4 that wasn't done. I had a 2001 5.4 16 valve that i changed the plugs, it was a MFer, but none broke. I soaked them with WD-40 and they came right out.
do a google search on it, tons of info
Bad thing is that I dont know if my engine is one of the bad ones, or if the warranty covers this issue. Ford should warranty the work when this happens.
gov motors vortec is better than ford triton, i like the rest of the fords better tho...
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