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Thanks to all who replied, at last we found the answer which mat be worth checking if you get similar problem.
After checking all components for tolerance and having the latest set of discs checked by an independent test house and found to be within spec we were baffled.
We decided to put the parts back and checked at every stage. The left side no problem, but as we put the right side together we tightened down the caliper holding bolts with the ratchet and everything felt fine. However when we came to torque the bolts the top bolt even though tight with the ratchet kept moving with the torque wrench. We decided to take the bolt out and found that the hole was completely corroded and the bolt was struggling to get through it.
It seems the bolt had probably never been all the way through from the factory as we had to tap the threads to clear them. Once done the bolt went all the way down and seems fine.
Because these calipers bolt on from the front rather than the side as is usual with most calipers, the bottom bolt and loctite had done a good job of holding the caliper in place. I guess over a period of time however the strain being put on the caliper bolt by the braking forces had allowed the bottom bolt to loose just enough grip to make the caliper move so causing the judder under light braking.
Just goes to show that even though the car had been in for two sets of disc change, nobody picked up the problem, probably because no one followed the instruction to torque the bolts, which would have instantly picked up the problem.
I will put something on the site in the future to let you know if I get further problems
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