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I bought a voltage regulator with new brushes which ended up being a waste of money. The symptoms didn't change at all. I bit the bullet and spent the $100 on a new alternator. Everything works great now. Even better than before. The stumble after start up is gone and the voltage gauge hangs above the half way with lights, heater and defroster on at idle. I love it. I have no idea what was wrong with the old alternator. I suspect is was the diodes which the test machine might have missed.
Thanks to everyone for contributing your tips and experience.
Justin
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