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I have a 1996 Econoline Club Wagon XLT 12-Passenger Van it is equipped with the heavy-duty towing package, (4:11 rear gear) it is my personal vehicle that gets used as a second vehicle, parts mover, or a tow vehicle to pull an enclosed car trailer. The only modification on the vehicle is an electric trailer brake control box that I put on several years ago when I first got the vehicle. The issue I'm having is with the electrical/charging system. The vehicle seems to have a low charging problem like it is voltage regulator issue. Since the voltage regulator is part of the alternator I replaced the alternator, but the condition continued so I put the old alternator back on. Intermittently the voltage gage will quickly jump down to 0 and pop right back up to normal. If I’m running at night this is very obvious as the headlights will dim out for a split second. Also if the cruise control is on and it starts doing acting up the cruise will disengage but can be reactivated by hitting the resume button. The engine will run normal the whole time the issue starts. I’ve searched through the forums but I found next to nothing on electrical/charging issues. The charging system seems to be low as it seems to slowly drain the batteries by day and much quicker by night. Both batteries are new (about 1 ½ years ago) and there is no problem with the batteries. I doubt that this is an issue strictly with the Econoline but I thought I’d post it here on Econoline board first. Any thoughts or suggestions on this issue? Thanks!

Jim
 

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Two things come to mind, either a bad wiring connection, or a short circuit.

First thing I'd do is check the voltage with the motor running and warm. You should see 13.8 volts give or take a few tenths.
 
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