ELECTRICAL GREMLINS [OVERCHARGING 440-3]

1...There is NO WAY I would drop back to a single wire VR.
2...Use an ohmeter to verify the field is isolated. The proper term IS NOT "dual field." The alternator does not have "dual" field(s). It has two field TERMINALS, and the proper term is "isolated field" as opposed to the 69/ earlier which having one field terminal, is "grounded field."

3...I would NOT assume your alternator is fried or unfixable. I would first see if it is returnable UNDER WARRANTY as defective, and if not see (as suggested above) if you can get the proper brush/ insulator hardware.

Once you identify the problem you will see it is a simple mechanical puzzle. lt is almost always a matter of incorrect brush hardware or missing insulator

The rebuilders are hacks. Terrible. This poor output from rebuilders has been going on since I sold parts IN THE SEVENTIES and EIGHTIES. Yeh. I'm old. 75