FLB76 said:
Before I get a replacement, is there any wiring that should be checked to keep another alternator from failing?
Just the heavy brown wire to the battery (especially where it joins with the battery cable) and the ground path from the alternator to the battery. Some people have reported trouble getting a good ground through the alternator mount, and added a heavy ground wire from the alternator case to the battery ground cable (but I don't see how you could fail to get a good ground through the mount if the bolts are tight).
FWIW I went through the same thing a few years back on the wife's Toyota. Went through 5 or 6 rebuilt alternators until we found one that would last more than six months. Car wiring was checked several times, all questionable components replaced (including the battery); but on the final go-round the only thing that changed was the alternator itself. That one is still working today (though we gave the car to my daughter). Fortunately the vendor replaced them under warranty, but it was still a giant hassle.
As I see it, the rebuilders are having the same problem with poor quality parts that we have.
PS the Bosch alternator that Hondo mentions is a good alternative. It bolts right up, takes the same plug and everything (but usually does need the little brown wire). However, they seem to have become hard to find recently. All of the on-line vendors that used to carry them don't have them now, and my local FLAPS said they couldn't even order one (although they could send mine out to be rebuilt).
There is also a Delco equivalent, which may or may not be easier to find.