Just an update on the alternator after having it tested and tearing it down. ONE of the brushes was worn so bad it would occassionally make contact with the slip ring. The brush that was making contact cut a serious groove in the slip ring. Guy at the alternator shop told me that if it wasn't for motorcraft alternators they would be out of business. Sad.....so sad. Best trucks on the planet with crappy alternators of all things.