Stick a multimeter on the alternator output post (not the battery) and ground and measure DC volts at idle then at 2500+ revs without and with electrical load.
Next switch to AC volts and measure the same post at idle and 2500+ rpm.
Post up your results minimum and maximum.
My early guess is bad connections or worn brushes but definitely not a whole new alternator.
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2002 S60 SE D5 Manual
209000 miles
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