redfirepearlgt
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Very interesting. Was just reading about the alternator unit on 3V GT's. There is actually a one way clutch in the alternator pulley that disengages during "high accelerator rates" of the engine. It's function is described as reducing NVH in the belt system at higher RPM. Don't know if this is a friction style clutch of mesh style clutch mechanism. But if it begins disconnecting at lower RPM, less voltage generation will be cause or NO voltage generation. This may not be detected at the lower speeds a parts store would spin the alternator at when testing which may explain why they sometimes test good. Check the manual on the theory. I'm taking straight from the Ford tech manuals. Sounds weird I know. But it's there. Oddly the 4.0L unit does not have this device. According to specs the alternator needs to spin at 1800 rpm (not engine RPM) minimum to produce max current output.