My alternator in my explorer - 03 postal model- stopped charging. I replaced the voltage regulator bc I figured that might be the cheapest fix. However after I installed the new VR I took the alternator to the local advance auto and they tested it. It still failed. It is quiet as a mouse so I think the bearings are still good. What else could it be and is it possible to rebuild it or should I just suck it up and buy a whole new unit?

 

You do have a few options.
One, you could exchange it with a rebuilt unit from FORD !
Two- you could take it to a local rebuilder (starter -alternator repair) and they should be able to repair it, (usually lowest cost option)
Three- Exchange it with a local parts store, if they have one, sometimes not always the best option.

 

Get a new alternator instead of a reman.Don't mess with rebuilding the original. I would get one either from a NAPA, Federated store or the dealer and make sure you save the receipt. I would stay away from any unit from the big chains such as Autozone, Oreilly etc.

 

I would add a little addl info.
It would be nice to get a brand new 130 amp alt, but expect to leave a good part of your wallet there. They are not cheap!! Plus you get to keep your old defective alt, what for ??? Some brand new ones are not the same quality unless purchased from Ford.
Local rebuilders have the equip to verify proper operation AND if there is any problem, they are close by and will guaranty their work .
I have yet to get a defective Reman alt from Ford.