GTjoey,
If you read his original post, he is experiencing an intermittent problem. The battery could not be low, as there is no evidence of this. Think about it, the car starts fine. Cranking over a cold engine requires up to several hundreds of amps! A weak battery simply couldn't do this. Once the engine is running, the alternator will provide up to 60 amps, most of that is more than adequate to run everything in the car along with charging a low battery. The system (battery) voltage will be roughly 13.5 to 14.5 volts when the engine is running (depending on day vs. night and engine RPM). The voltage regulator's job is to ensure this. If the system voltage in the car dropped towards zero, even momentarily, the car engine would simply quit running! The battery voltage gauge monitors the system voltage via a computerized "Smart Box". The voltage gauge does not monitor the system voltage directly as older cars did. This is why I feel that there is a faulty connection or module. A faulty relay is not too likely in this car since I have spent several hours studying the wiring diagram. There are many relays, however, they usually are not used to control or switch low level signals such as those needed for any one of the gauges. Now, if a relay which powers the entire Smart Junction Box was failing or intermittent, the warning lights on the dash would probably flash like a pinball machine. The Ford manuals do not provide a theory of operation either, making precise troubleshooting very difficult. Due to the complexity of modern day automobiles, auto mechanics simply swap out modules rather than trying to pin point the exact problem. It's much faster and cheaper this way.
Am I missing something here? I do not wish to sound like a know-it-all, however I make my living designing all types of electronics. So, any comments would be appreciated. I hope that Lemansz can inform us of exactly was caused this problem.
Jay