I have not read this whole thread, but I had a similar issue with a different car. After 3 alternators that my son had a shop install. I noticed the negative battery cable could not be properly tightened. I fixed that with a hack saw but making the gap bigger, and has been fine since. For what it is worth the shop had the car at the time and was adamant the alternator and battery had to be replaced. I jumped it the parking lot and took it home and fixed it. No more alternator problems.
Short version, check your grounds.
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1991 240 Sedan auto
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