@Kumba - your response and added humor were both appreciated. I told the wife she was just addressed in the forum and her facial response was post worthy. Regardless, that sounds like an MF'ing headache and a much larger problem than i was hoping. I'll drop it by the dealer just to let them pretend to diagnos it - from there... it looks like i'll be 'baking'.
"Good Luck" is all I have to say. I bet they will tell you to get the tires balanced and if (or when) that doesn't fix it try to sell you some. You will probably also hear about bad rims. So how do you prove to them it's not rims? Simple. Take the rear tires off, run some lug nuts down on the rotor so it's all held in place, put the car up on a lift or jack stands, start it up, and slowly accelerate till you get the virbation/hum. This is literally what I had to MAKE my dealer do in order to prove that it couldn't POSSIBLY be the wheels or tires. And no, swapping tires front to back, which would make the out of balance vibration move with the tires, was not a good enough test for them. I had to literally drive the car with no tires before they went "Ohh, well, I guess it wasn't the tires/rims". And such is my dealing with most Ford dealers anymore.
Also, I had the units wrong, that's 250-degrees Celsius, NOT FAHRENHEIT! Most household ovens in the US would need to be set to about 450-F in order to get the metal to expand enough. If you are doing it right the bearings should just pop right out, if not fall out under their own weight. Preheat the oven, then put the knuckle in there for 30 minutes, see if the bearings will pop out, if not, shove it back in for another 30 minutes and check. If they still won't pop out, then stop, let the knuckle cool for a few hours, and take it to a machine shop. You will need a press at this point. If you need to tap the bearing out you should only need a small push. You shouldn't need to beat it loose, but just a tap to pop it out. Make sure you tap evenly around the circumference of the bearing so you don't get it sideways in the bore.
There is also more then one bearing in the knuckle. There's a small needle bearing for the CV shaft, then the big bearing that the hub rides on. Try to clean all the grease out that you can as the baking process will also bake the grease and harden it. Of course the needle bearing is only like $5, might just replace it for the hell of it anyways. The big wheel/hub bearing is like $25. Guess the prices went up since last I looked, or I was looking at the wrong thing.
The big bearing is a double sealed bearing. You will probably want to examine the state of the old bearing when it pops out. if the seals look like they melted then you will want to put the new bearing in the fridge or freezer to protect it when you slide it in the aluminum. You will also want to immediately sit the knuckle in front of a box fan on high to cool it so you don't damage the grease in the bearing or seal. You only have one chance to install the new bearings. Re-heating the knuckle with the new bearings in it isn't an option. So make sure you have everything in place before you start and once that bearing touches the aluminum commit to it. Don't sit there and double guess yourself. Tap it down, spin knuckle around, tap in second bearing, sit in front of fan, done. If you start and the bearing seizes for whatever reason, stop, sit knuckle in front of fan, allow to cool for a few hours, then take to a machine shop. You will have 30-second to maybe a minute before the aluminum cools and siezes on the bearing.
If it all sounds like too much work or hassle, you can just take the knuckle to a reputable machine shop and have them press the bearing in for you. Might only cost you a few bucks and you don't have to worry about it. Some prudent preparation work might help too. See if you can find some metal pipe that matches the bearing race diameters. That way you have something you can use as a punch to tap the bearing in or out. When installing the bearings, only tap on the outer race. When removing the bearings, you can tap anywhere you like. But again, they should more or less push right out when heated.
