A grounding problem or some other bad connection is quite possible. Take a good voltmeter and check the voltage from the negative battery terminal to different ground points: alternator case, regulator chassis, body. Any difference over a hundred millivolts is a serious problem. You can do the same thing with the positive cable to the alternator output and regulator sense lead.
If I recall correctly, Ford alternators regulate by grounding the field, so a bad connection between the regulator and vehicle ground might explain your symptoms.
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