Don't be suprised by the Temp guage only reading @ N or O. This is pretty normal on the Duratec. The Zetec on the other hand is known for reading much higher. Rob and I tested mine with the OBDII and found that the fan came on around 215f. As for the fan being dead. I thought for sure there was a recall pertaining to this. May be worth a little investigative work. Sorry to hear your having problems still. Hope you can get them resolved.