When I removed the alternator I took a tiny drill bit (fit inside the connector) and wrapped a small amount of steel wool around it by running the drill in reverse. I soaked the connector with electrical contact cleaner and ran the steel wool covered drill bit in reverse inside and out until the contact was as good as new. Lastly I cleaned all remnants of steel wool from the connector. It may still be a connector problem, but I don't believe it is due to poor contact. Before connecting the 2 contacts I applied a liberal amount of dielectric grease.
My present generator, 3 years and 10 months old, is nearing the time when the other 2 Advanced Auto generators failed so I figure replacing it is not a waste of money. When I do replace it I'll strip of the tape around the wires at the 2 connections and see if there are any frayed wires. If not and the new alternator does not cure my dash warning lights I'll go after the relay behind the glove box.
AA agreed if the alternator tested as bad they would sell me a re-manufactured Denso for the list price (137) minus the price of their lifetime guarantee alternator (70). Since it tested good they were unwilling to do the deal. While I currently don't think a new alternator will solve my problem I'll certainly let AA know if it does and reluctantly give them any future business.
