Did you use a torque wrench on the lug nuts?
I think I'd start by removing one wheel, replacing the lug nuts, then install a dial indicator and run the engine in gear. Any run-out more than.005" will cause the caliper to move back and forth on its slides. Worn spots on the slides will cause the pads to catch and clunk as they move over the rough spots.
Did you install a new rotor or used one? Used ones will have a round rust spot at the location of the bolt access hole in the hub. If not cleaned off, that rust will hold the rotor away from the hub causing a severe wobble.
Noise can also come from rust pitting and flaking on the back side of the rotor. When you reassemble everything, be sure to torque the lug nuts to 95 ft / lbs. Use brake assembly lube on the caliper slides too.
Sunday, April 5th, 2009 AT 9:40 AM