Sometimes an alternator with a weak diode(s)can test out fine, but can still trigger the light. I believe the problem is in your alternator. Good luck.
The voltage regulator is locate in one of two places. ***The voltage regulator is located in the alternator if you have an IAR type alternator*** ***The external voltage regulator (for the EVR-type alternators) is located on the driver's side wall, right next to the battery. It's much easier to see and/or remove if you remove the battery first. It has "Motorcraft" in raised lettering across the front*** I just had to remove mine.
Alternator is not recharging the battery. Have the alternator tested or test it yourself with a volt meter. You should read from 13.5 to 15.5 volts DC at the battery with the engine running. If any lower the alternator needs replacing. We had already changed the alternator, and bought a new battery. It is still doing the same thing. It will idle ok. When you drive it, you go down the road around a mile or so, and the darn thing shuts down again, and the battery is dead again. Are you sure the serpentine belt is not slipping? Did you replace the voltage regulator along with the alternator? If you answer yes to both these questions then I suspect you have the alternator wired incorrectly or the battery cables need replacing. The latter is what I suspect is the problem. You may have an internal break in one of the battery cables that just does not show up all the time. Look for a bulge in the cable especially a cable running next the the exhaust.
As often as the alternator fails... ;)The alternator is not a 'consumable' type of part that requires routine maintenance/replacement - like a serpentine belt, brake pads, etc.Many repair shops and auto parts stores offer inexpensive or free alternator & battery testing.Be sure to test before replacing!NOTE: it is a little known fact that a weak or failing battery is a major contributor to premature alternator death. Any battery that is 4 years old is a prime candidate for replacement.See "Related Questions" below for information on how-to replace Taurus / Sable alternators
The problem is in the voltage regulator, BUT you may NOT need a new a whole new alternator !- The Voltage regulator block is easily replaceable in these alternators and costs about $30. ( compared to over 200 for an alternator). I have done this repair in 3 Taurus's.- If you can't fix this, I would advise taking it to an independent 'Alternator /starter' business. I see many in Canada. You usually get a good repair cheaper than at dealer.
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