Anybody out there have any ideas?
Even now, the caliper moves a bit when pressure is applied. It seems like it would/should, since there's no rear fasteners holding this thing in place, just 2 pins.
You might have bent the pins and now the caliper cannot move as much as needed.
There is a related problem with not getting the caliper properly positioned on the pins during reassembly and bending the mount or caliper, but I cannot remember the specifics.