Answers

I assume the replacement alternator was a rebuilt unit. Some rebuilders do not test their products thoroughly, or do not install all new parts; and there are many units which have to be returned as a result. The alternators sold by NAPA stores under their own brand are more reliable than any other source I have found. This problem almost certainly comes from a defective alternator or voltage regulator. The voltage regulator is located inside that alternator, and can be replaced separately; but when things like that happen, the whole alternator is usually replaced. But you would have to catch it at a time when it was not working; and then hope the flexing and jostling of removing and transporting it did not get it going again.

One other thing that could cause such a problem is if the battery was not securely grounded to BOTH the engine, and to the vehicle body. There should either be a second ground wire from the battery to the body; or a dedicated ground wire from the engine to a bolt on the firewall. If these auxiliary ground wires have been removed; all sorts of weird electrical problems can develop.

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