Chevrolet Repair: 06 1500hd brakes, caliper brackets, chevy 1500hd

Question
Hi, I have a 06 Chevy 1500hd canada built. I am an ASE mechanic and this is driving me crazy!!! The front brake pads on my truck rattle when going over bumps. The noise stops when i push on the brake pedal. Light or hard braking will stop the noise. I have replaced the brake pads 4 times, put new calipers on, and have replace the caliper brackets with gm dealer parts. Every time i put new pads on the noise is gone for about 1000 miles, then returns. Everytime i get the truck up on a lift and take the wheels off when the noise is present, the brake pads have movement in the caliper bracket. I have been lucky since i work at a shop to be able to warranty out the brake pads each time. I am at a loss of why the ears on all 4 different brands of pads keep getting worn out. Right now on the truck is all new factory gm dealer parts - Calipers, Caliper Brackets, Pads, and Anti Rattle Clips. There is one other thing going on with the brakes that im not sure if it's related. About every 3-4 weeks, i'll be sitting at a stop light and when i go to take off,  the brakes stick for about a .5seconds then release. Doesn't happen very often at all, but not sure if this all has to do with the hydralic portion of the brakes. Also have replaced the rear calipers and pads from normal wear and tear, and I have had no problems with the rear brakes. In over ten years of being an ASE mechanic i have not run into this before. Please help so i can learn and pass the information on to others. Thanks

Answer
HI GRAHAM,WELL AROUND THESE PARTS WE DO NOT HAVE THIS TYPE OF PROBLEM BECAUSE OF OUR RUSTY CLIMATE...SALT BELT USA. .BUT YOU GUYS UP IN TEXAS DONT KNOW HOW LUCKY YOU ARE TO WORK ON CARS WITH NO RUST..WE NEED THE SMOKE WRENCH TO REMOVE EVERY BOLT UNDER THE CAR..LET ME ANSWER YOUR LAST QUESTION FIRST,WE HAVE HAD 3 OR 4 OF THESE CHEVY TRUCKS THAT THE PUSH ROD IN THE BRAKE BOOSTER STICKS HOLDING THE PUSH ROD TO THE MASTER CYLINDER ON FOR A SECOND AND THEN RELEASES. WE HAVE REPLACED THE BOOSTER ON 2 OF THESE TRUCKS TO DATE AND THE PROBLEM HAS NOT RETURNED..  
I WOULD LOOK INTO THIS AREA OF THE SYSTEM FIRST BEFORE DOING ANYTHING ELSE. NOW FOR YOUR FIRST QUESTION, I WILL BE HONEST WITH YOU, OUR SHOP HAS NOT RUN INTO THIS TYPE OF PROBLEM..OUR PROBLEM IS THE BRAKE PADS RUST IN PLACE ON THE ANTI-RATTLE CLIPS. SOUNDS LIKE YOUR PAD EARS ARE SPREADING. WITH GM PADS THIS SURPRISES ME. YOU DO REALIZE THAT THE PADS SHOULD NOT FIT REAL TIGHT ON THE CLIPS ?? BUT SAYING THIS DOES NOT MEAN THAT THE PADS SHOULD RATTLE EITHER. I HAVE HEARD THE PADS CLICK WHEN BRAKING FROM FOWARD TO REVERS, BUT NO RATTLE OVER BUMPS..I DO HAVE A SUGGESTION FOR YOU, IS YOUR SHOP A MEMBER OF IATN ?? IF SO ASK THEM THAT QUESTION. IF YOU DO NOT BELONG TO THAT GROUP CALL UP THE WAGNER HELP LINE, THEY RUN INTO STRANGE PROBLEMS LIKE THIS..ARE YOU A MEMEBER OF DELCO WORK FORCE ?? IF SO CK FOR A TECH SERVICE BULLETIN.. I WISH I COULD OF HELPED YOU ON THIS BUT !!! SORRY.. IF YOU DO FIND  OUT LET ME KNOW..I WILL KEEP IT IN MY MEMORY BANKS..HOPE THIS HELPS YOU ,,,,TOM..