Oh hey, It was my BC anniversary. Thanks for noticing. I unknowingly celebrated by putting in a new radiator... but that'* another story.

It looks like it'll be worth looking into the bearing possibility. I'd have to try to get my hands on a puller and a heater. Not really sure where those can be found... any ideas there?

Would the bearing noise get louder with more load though? My noise is barely there when the lights are off, blower on low, etc. But it'* nearly as loud as a supercharger at 3/4 throttle breathing through a CAI, when everything is turned on. Would a bearing noise vary like that?

I also wonder if this can be done to all years/models. I know that the alternators on the new ones are different than on my '89.

Thanks for all of the info so far. If anyone has done this, and can give detailed instructions (or an opinion on how long it lasted, how difficult it was, etc.) that would be great too.

Thats the best description of alternator bearing wear I've seen here yet Current demand will put more load on the alternator which in turn puts more preassure on the bearings, like wise as the engine rpm increases the alternator spins faster adding side load to the bearing.

Look for an electric motor rewind shop, they might help out with tools?

There are still places that will rewind/rebuild Alternators for you. My plan is to have this done to the DP alternator I'm currently running (whenever it goes south). It'* usually less than half the price of a new alt. They can replace the windings, diodes, and bearings. I've had this done right here in town to two other GM cars in the last 10 years.

Ford'* had a boatload of recalls on the Focus, including two or three real nasties on the early-production runs. Suggest you get back to the Ford dealer, give him the VIN for your car and ask for a listing of all recalls that involve it. One or more may be electrical. (I'm pretty sure there are electrical recalls outstanding for the Focus, but don't recall the details.)