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No roaming? Still roams... Android settings??

Hi all,

I have a roaming problem with my Xperia Arc (the phone is not the problem). I live in France very close to the Swiss border, I work in Switzerland and I my provider is Orange France.
I set my phone on manual network selection because i don't want to pay for roaming charges.
When I first got my phone (2 months ago), all was fine for the first few days. Orange France 3G has a low coverage over the swiss border but the 2G mode (Edge) covers basically every where I go.
So as I said, for 3-4 days, all went well. The phone switched from 3G to 2G or to no network coverage and back but never roamed. Then, all of a sudden, I found it on Orange Swiss and the little 'R' next to the signal strength was showing. So I immediately went to select a network operator and to my surprise, I couldn't find Orange France anywhere. It just disappeared and only reappeared a mile or so from the border back into France. Funniest thing is that even then, it only found the 3G network and no 2G at all...
I called Sony and we factory reset the phone: that didn't work. I called Orange France and we reset the phone: that didn't work. We changed the SIM card: That didn't work either so Orange said they would change the phone.
The new phone arrived and the exact same thing happened: 3-4 days, all was well and then all of a sudden, phone started roaming and couldn't 'see' any 2G networks.
Called Orange again and they sent a new phone. And you guessed it: Same thing happened...!
I just called Sony again and they are saying that the phone is again faulty...

Somehow I have a feeling this is due to Android or something in the settings which is wrong. So here are my settings in the 'Mobile network settings':
Data enabled is ticked
Data roaming is unticked
Network Mode is 'Preferred: WCDMA (preferred)/GSM'
Access Point Names: Chosen is 'Orange World' (Other options are 'Orange Entreprises - orange-mib' which is not chosen and 'Orange MMS - orange.acte' with no possible choice)
Then, under Network Operators, Search Mode is 'Select Manually'

Anyone have any idea what's wrong with my settings or what I should check?

Many many thanks,

Pegasus
 
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