What was found
MFG FABRICATED AN IN-LINE RESISTOR FROM THE ALTERNATOR TO THE VOLTAGE REGULATOR. THE RESISTOR WAS LOCATED APPROXIMATELY 2 INCHES FROM AUX TERMINAL ON ALTERNATOR. IT WAS STRENGTHENED WITH MULTIPLE LAYERS OF HEAT-SHRINK AND TERMINAL WAS CRIMPED ON THE SOLID WIRE LEAD OF THE RESISTOR. THE AIRCRAFT HAD INTERMITTENT ALT FAIL WARNING BUT HAD NORMAL, POSITIVE SYSTEM CHARGING. UPON DISCOVERY OF THE FAULT, THE RESISTOR LEAD WAS HELD IN THE TERMINAL CRIMP BY THE HEAT SHRINK BUT THE SOLID WIRE WAS BROKEN, MOMENTARILY MAKING CONTACT CAUSING THE FAULT. THE PROBLEM WAS CORRECTED BY SOLDERING A SMALL SECTION OF WIRE TO THE RESISTOR AND INSTALLING A NEW TERMINAL TO WIRE. MFG CUSTOMER SUPPORT WAS CONTACTED AND THEY WERE A