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Thanks everybody for the insight. I took it back to the dealership for diagnosis and they determined I got a defective remanufactured alternator, but that it was installed correctly (WHEW!). Was glad they confirmed it was installed correctly. The service advisor said both he and the technician...

Good stuff, thanks for the advice. I've got a list of things to check when I get home tonight :)

battery was at about 12.5V (analog multimeter in my dark garage) this morning with the engine running for a couple of minutes.

Thanks for the reply, and the welcome to the group. I forgot to check the main alternator fuse so will check that tonight. I'll also go over and recheck the wire connections. Would be very disappointed if the replacement alternator was defective. At the least, I do have a service appointment...

Local Ford dealership identified the alternator bearings as the source of a sound I had been hearing on my Explorer with 100k miles, quoted $1200 to replace. That sounded like a lot so I picked up a remanufactured part from a local auto parts store that fits my vehicle. After the (long) process...