escape alternator probs.

hi im a mechanic at a ford dealer and weve got the whole shop stumped on this one. 2005 escape with the v6 auto replaced the battery about one month ago now its back. car runs fine but only puts out 12.5 volts @ 30amps. under load we have 12.5 volts @ 100 plus amps! we have tried three alternators, a battery, bypassing the cables, you name it. we even tried a kmown good alt from a newer escape. Ford has a test where you unplug the conn. to the alt and rev the motor to 4000 rpm and the alt will default to 14 volts. that test didnt work. However we tried that test on a good escape and it worked! any ideas or previous exp. would be great. dan.

I have a 05 escape doing the same thing. I replaced the battery and found it would not start the car after 1 week. A quick jump would start it and power all the accessories so I thought the alternator was OK. I checked my voltage wile it was running and am only getting ~12.4 volts instead of the expected 13.5 volts. The alternator for this is $265 and hard to remove so I was hoping someone could help explain this.
Thanks

Check for a burned out bulb in the dash for the charge indicator light. This bulb excites the field for the alternator. I've also had to change the ammeter as they didn't work properly and excite the field.

A good alternator shop can repair your alternator a lot cheaper than $279.00.
They can also install a self rectifying voltage regulator just a 1 wire hookup.
They do this for tractors and boats but I would fix the problem in a car of this age. It depends on your wallet.

What ever did the Ford mechanics find?

Just like the Focus, make sure the connector to the back of the alsternator does not have a bad connection like a wire coming out.

yah this is interesting what did they say was wrong? diodes or regulater was it? or maybe brushes or ?