First thing I'd do, is use an infrared temp gun and watch the ACTUAL temperature that the engine runs at (at the thermostat outlet), at the actual point that the fans kick on, just to VERIFY that they ARE, in fact, coming on too late. You may have a faulty reading temp gauge. Once you verify that the temp is too high (outside specs), when fans kick on, then figure out WHY. Meaning, Is it the ECM, ECT sensor out of range, or some other issue (maybe resistance in a wire or connector)? There IS a logical explaination to your problem, and just because FORD dealer couldn't fix it, doesn't mean it's some big huge unfixable problem. It just means that that technician that was working on your car that day DIDN'T know what he was doing (actually quite common today in our day and age). It IS hard to find good techs these days, but this is why I prefer fixing my own cars, and eventually even became a tech myself, because I can take the time to study up and figure out what the real problem is, and now have figured out how to make a living doing so. I think you could figure out how to fix this problem on your own car, because anything else you do to it, will just be a bandaid. Better to fix it right. So go find an infrared temp gun, or pay a shop like 20 bucks or something, to give you an actual temp reading at the thermostat outlet housing when the fans turn on, and then go from there. That's what I'd do.
