Ford Repair Questions? Ask a Mechanic for Answers ASAP
Unfortunately its more than likely the alternator again. Repeat alternator replacement is very common on these.
Ford never published a bulletin or recall but they should have. In my opinion the alternator is susceptible to failure due to the proximity to the exhaust manifold and fails because of the heat that its exposed to. I have also seen multiple failures of aftermarket alternators as compared to Ford units. There is venting ductwork on the back of the alternator which is crucial for alternator cooling. It is difficult to remove and install the duct work during alternator replacement and I have seen technicians leave it off to save time, not knowing that by leaving the ductwork off the alternator is even more susceptible to heat failure from the manifold.