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it does signal a bigger issue, I just replaced my ALT because it left me stranded on the side of the road, and it tested just fine in the store, so take their test results with a large grain of salt. it sounds like you may have gotten some sort of spike in your alt and it may have done some damage to the diodes but left the windings in tact. if you replaced it a year ago i would ask them to warranty it, or just buy a new one. i would not put that old one back on, since it is such a pain in the ass. good luck, and i would make sure to go over all your fuses and relays since stuff got hot in that circuit.
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