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Sounds like "Danger...Danger to me!"

It's possible the rotor was re-assembled incorrectly when the wheel studs were pressed back in.

A good rule of thumb is you need a minimum thread engagement equal to the diameter of the stud or bolt your using. For a 1/2" stud that's about 10 turns if you have 20 threads per inch.

Could the rotor be installed on the wrong side of the hub. How does the new one compare to the one you took off?
 
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