It sounds like you've exhausted all the 'usual suspects'. All I can think of is that something was assembled incorrectly on that wheel and when you went back together, you duplicated the original incorrect assembly. Have you compared the other side to the problem child?
I have compared, removed and inspected all parts and reassembled a couple of times. It did this prior to me working on the brakes as well so I don't believe it's something that I have done. I just exacerbated the problem when I put a new components in.
