Karl - I�ve successfully ruined Delco and Mopar (Chrysler) alternators by disconnecting the battery while running � no reason to think it will not smoke a Motorcraft alternator too(!)
A possible solution is to provide a dash switch wired into the alternator field circuit. The driver would open this switch and leave it open during the tech inspection. The alternator will thus be �turned off� (not providing current) and therefore unable to provide a burst of voltage and destroy itself in response to the sudden open circuit when the inspector pulls the battery disconnect.
A side benefit is the driver can leave switch off - thus the alternator disabled - during the run. Depending on the car's electrical load this might yield an additional 1 HP or so at the rear wheels during a run.
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