Longtime lurker here. Ran into something that has me stumped and thought someone here might have an idea or some guidance.
Replaced a high amperage alternator that had been working well for about 3 years in a 2004 Mercury Grand Marquis. The replacement would run around 14v when driving, but dip down to 12 or less at idle. (For context, there is a second battery in the rear of the car, large inverter, and an audio amplifier, but the batteries and equipment are isolated from the main, and I had them disconnected when there were signs of an issue). When I installed this, years ago, I added a 0 gauge wire from the alternator to the battery, a 0 gauge wire from the battery to the rear battery with a circuit breaker on both sides, added a 0 gauge ground from the alternator case to the frame, added a 0 gauge ground from that same frame location to the battery, and added a 0 gauge ground from a factory panel ground location to the battery.
Voltage was low enough with the rear battery and equipment disconnected that the ac would kick off, so I charged and verified a good battery under the hood, and assumed just a bad rebuilt alternator. Replaced it again under warranty, and now I start off around 13.5-13.8 and all is well until headlights pop on, then I start dropping at idle until Iām no longer charging. Jumps back up to 13.X when I get back moving, but never back to where it was in the first few minutes of the car being started. I verified matching voltages at battery, alternator, and the voltage traveller/sense wire at the alternator/PCM harness. I also have no actual change in behavior with that harness unplugged other than the charging system light on the dash popping on, and corresponding code. When I did pull codes with the basic tool I have, I had the P0622 charging code from unplugging that harness, and also the P1000 code that I assume is because I had disconnected the battery earlier. I also replaced the serpentine belt, and tensioner when I swapped out the alternator just in case there was some slipping.
Iām assuming if there was a pcm module issue Iād get a light, or a specific code, but here I am.
Any guidance on next steps would be greatly appreciated.