If you were with me on that journey, you might recall that it ended, unresolved, when I ran out of time and energy to continue.
Recently, I had occasion to remove the alternator for another reason, and this suited as an ideal opportunity to open it up and see if there was a problem inside. As it turned out, everything inside was in perfect condition - the brushes were like new, all 6 diodes were working and all the connections were tight.
You might recall also from that 2010 journey that I cast suspicion on the connector that mates with the alternator, delivering the bootstrap voltage. So I pulled the terminals out of the nylon connector, and found, yes you guessed it, that they were dirty and bent enough that a poor connection was being made. Cleaning and restoring the terminals to their proper shape completely resolved the issue.
To release a terminal from the housing, all you need to do is, working from the front of the connector, depress the tang with a knife, small screwdriver, stiff wire, or whatever fits into the space, and you can then withdraw the terminal out the back of the connector.