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As for the problem. I know in the past dealing with LED's, that sometimes tossing at least one incandescent bulb in the system sometimes help issues. Kinda becomes a buffer to help the system work together.
The incandescent bulb adds load or takes more current to run. That is the problem with LED's, they do not take enough power to light, and this causes problems in some older circuits. That is why they also make load resistors you can add across the LED bulbs to also make the circuit work correctly. Just like the incandescent bulb, the resistor adds load to the circuit.
Were you able to run a test with the headlights and heater fan? If AC ripple was the culprit, I had another thought along those same lines. Try running the engine at different RPMs and see if anything changes. Sometimes, the spikes can be more pronounced at lower speed, due to more time between them. At higher RPM, they can tend to blend together.
This is not always the case, but it’s quick and easy to try. Please keep us updated.
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