How about it being as simple as this; the gauges are crappy gauges?
Now even though this a off-the-cuff comment it is partially based in fact.
AutoMeter; a company that has for many years created wonderful gauges that are recognized and used by many with very few redundant failures created these gauges; or maybe better put created them based on Ford’s directive. I was told long ago that when AutoMeter was brought on board with the Ford GT project that they presented to Ford at least two options; one of which was a design consistent with their normal gauge production and the other a less expensive option based on Ford’s directive the latter of which was selected by Ford. Now is this true; I can only say that the comments have now been shared by more than one source and they are not connected with each other as such I suspect yes.
So what is the answer; an alternate battery design “no” as measuring surface and load voltage of a battery is very easy and when like values are seen the net result from the battery will also be the same; voltage and amperage does not know from where it comes; thinking otherwise makes no sense.
So why are some of the gals affected and others have remained completely under the proverbial radar; I suspect that this has to do with when the gals were assembled. There are 8 primary grounding points all of which have a painted surface with two of them being under the dash and this could be the cause; sadly to clean those under the dash requires one to; remove and discard the polished stainless steel door sill inserts, remove the door sill cover, then remove the leather kick panel at the base of the A pillar at which point they are right there.
Could it be that some folks have less than stellar batteries as such upon start up there is a voltage spike that causes the gauge to fail; maybe. Could it be that as with sadly, any typical production that some of the batches of gauges produced were/are simply crap, maybe.
The bottom line IMO is we have been and will continue look for a fix for what I consider to be a design flaw; this flaw either in the gauges and or the OEM interface however we are doing this knowing full well that the fix would be a patch and not the correcting of the issue.
Now back to an earlier comment with regards to the primary grounding points; there is one at the front of each frame rail accessible once the inner fender liner is removed, there is the one at the battery negative cable to the chassis, there is one under the upper portion of each kick panel, there is one as the rear of each frame rail that are easy to access if you remove the rear portion of the rear wheel liner, and the one that goes from the chassis to the black on the driver side and this is easy to access with the belly pans off.
So if it were me I would swallow the pill and purchase a new pair of polished stainless steel door sill inserts, remove the front inner fender liners, remove the rear portion of the rear wheel liners, and remove the belly pans and at each grounding point remove the 10mm head bolt and then remove the paint from the surfaces and also run a thread chaser through the holes to make certain that all is clean and then methodically reassemble everything.
The process could be completed in a casual Saturday afternoon with the only expense being the polished stainless steel door sill inserts, 20 black pin in retainers, and a piece of sandpaper.
My gut tells me that this is not only a prudent but also viable plan.
If I can assist in any way please let me know as this is not rocket science.
Takes care
Shadowman