Clunking noise while braking...please help

You need to grease your caliper bolt pins and put disc brake quiet on the back side of your pads to make the noise go away. Make sure your lug nuts are on tight = 80ft lbs. When you turn the wheel the rotor should be solid with the rim and caliper bracket.

 

wow, it sounds like a spring being tightened, but i don't think there are any in there.
how many km's on her?

 

that's not much, were the brakes that worn?

why would you have to change the rotor stud bolts?

 

hmm, i'm not sure of the proper installation method, possibly pulling them in by snugging up the nuts to the proper torque?
i'm not sure what damage hammering them in might do, you've already replaced the bearings.
maybe you need to disassemble everything and start over. the big question is why the noise would go away for awhile with new pads and rotors. a slightly bent axle might cause them to wear unevenly?

 

I think the anti-rattle clips, the brass-plated clips at the ends of the pads, are installed wrong, or broken, missing a piece. Maybe. Here's a screen-grab from the video:



And here's a pic of ours, again, left side front rotor:



Or, is it a different anti-rattle clip design, different part of the world??

Also shim pads appear to be missing.

 

Stud failure, a couple of things come to mind, Firstly, over-torqued lug nuts. This is the obvious one. But also, maybe just removing the lug nuts when the wheel is hot, heat-expansion of metals might have led to seizure?

 

Just another thought: the wheel should not get any more than slightly warm normally. If it's very hot, say due to excessive brake drag, for whatever reason, that again might have heated up the studs enough that the nuts seize when you attempt to remove.