NHTSA Complaint #10248213 — 2005 FORD F-150

I HAVE A 2005 FORD WITH THE 5.4 LT. ENGINE. AT THE 63,000 MILE MARK I DECIDED TO REPLACE THE SPARK PLUGS DUE TO SLIGHT IDLE PROBLEM. AFTER SPENDING $102.00 ON A NEW SET OF SPARK PLUGS I RAN INTO THE PROBLEM OF THE SPARK PLUG'S LOWER HALF BREAKING INSIDE THE CYLINDER HEAD, IT TOOK ME TWO DAYS TO COMPLETE THE REPLACEMENT DUE TO A FAULTY DESIGN OF THE SPARK PLUGS. THE SPARK PLUG STEEL SHELL IS MADE OF TWO PARTS A TOP HALF THAT HAS THE THREADS MADE ONTO IT AND THE LOWER HALF THAT HAS THE HOOD WERE THE GAP IS MADE BETWEEN THE ELECTRODE AND ITSELF ALLOWING FOR A SPARK TO HAPPEN. THE PROBLEM BEING IN THAT THESE TWO PARTS ARE ONLY CRIMPED TOGETHER, THE CRIMPING IS NOT STRONG ENOUGH AND THE LOWER HALF DUE TO THE CARBON BUILD UP MAINTAINS ITSELF JAMMED IN THE CYLINDER HEAD WHILE THE TOP PART SLIPS AT THE CRIMPING AREA TURNS AND IS THREADED OUT CAUSING THE SEPARATION, I WAS GOING TO WELD THE TWO PARTS TOGETHER SO THAT THE NEXT TIME I HAD TO CHANGE THE SPARK PLUGS THE LOWER HALF WOULD TURN WITH THE TOP HALF OF ALLOWING IT TO BREAK ITSELF FREE FROM THE CARBON BUILD UP AND NOT BREAK IN THE CYLINDER HEAD BUT DECIDED NOT TO GO WITH IT TOO MUCH TROUBLE I'LL GET RID OF THE TRUCK BEFORE THE SPARK PLUG NEED REPLACING. WELL WHAT I HOPE TO GET OUT OF THIS IS THAT FORD REVAMPS IT'S SPARK PLUG DESIGN BY EITHER WELDING THESE TWO PARTS TOGETHER OR MAKING THE SPARK PLUG SHELL A 1 PIECE SO THAT I DON'T HAVE THIS PROBLEM AGAIN IF I DO DECIDE TO BUY ANOTHER FORD PRODUCT AFTER THE HELL I HAD TO GO THOUGH CHANGING THESE SPARK PLUGS. *TR