This is a Ford engineering problem thanks to a bean counter. They decided to save .2 seconds per head by only drilling 3 threads into the plug holes. ALL 2V SOHC heads face this issue (96-04 Mustang GT, 98-10 Crown Vic/Grand Marq/Town Car, F150, E150, etc). The DOHC heads did not have this issue, nor the 3V SOHC heads on the 05-10 Mustang. However, the 5.4 2V had the exact same heads (and thus, the exact same problem) and the newer 3V one have their own unique plug problem.
I've never been a fan of this engine in SOHC form, and have posted that displeasure numerous times. At $300+ per plug hole (and there's 8 of them), it's really not cost-effective to "pre-fix" the stupid things.
I dunno what I'm going to do. My car is coming up on 150K miles (I've put nearly 27K on it) and it's going to need a lot of maintenance soon (trans service, ABS fixed, brake calipers, front shocks, etc) and added to the plug problem I think it's time to let it go. It's stranded 40 miles away right now.
Michael Pinto - GoKart / 93 Miata STS / 01 P71 Interceptor