Well, I finally discovered the real alt problem! I SO didn't want to replace that alt and something just didn't seem right. I was picking away at the V90 today and I decided to finally take it for a drive. While it was out I thought I'd compare it's battery and charging voltages to the 960's. I also checked our '98 Sierra. I used our multimeter and I also borrowed my mechanic's. Our meter was way off (too high) and my mechanic's would show the voltage creeping up on the 960's battery while it wasn't running! So, I went to my mechanic and showed him what his meter did. He said that's weird and went into the shop and found a brand new meter that a parts guy reciently convinced him to buy. We tried that and it gave a totally different reading on a '93 245 then his old meter did. He gave me the new meter and told me to take it home and try it on the 960. So I did: The 960's battery read ~12.7 with the car off and charging was around 14.3. The V90 read around 12 with the car off and ~13.8 with it running. The Sierra was about the same as the 960 and our '04 Liberty was about the same as the V90. So, I guess the 960's alt is just fine, maybe a little different then the V90 as it's a '94 and the specs may be slightly different then the '95+ 960s(?) I knew something didn't make sense (no boiling battery, same reading as the truck, no blown bulbs, etc). Quite annoying though, as I would have rather not wasted all that time trying to figure out what was going on.

Now I just have to figure out what's happening with the darn ECC fan! Hopefully I'll get that sorted out on the weekend or next week. I guess I'll try disconnecting the fan and see if the fuse still blows when the fan dial is turned... Any other suggestions if that doesn't work?

Thanks very much for the help so far guys!
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Chris. Halifax N.S. '98 V90 > 195K km, '94 964 > 88K mi. SOLD: '91 745T and '91 745 NA (I miss both of them!).