rattling from front wheels

did you just replace tehm? where did you get them if you did, pulled the wheel and it looks like the rubber that the caliper slides on, tie rods are tight 9new both inner and outer) sway bar is new with bushings
 
Probably the rubber "slider bushings" that the calipers slide on. Mine did this once.Its a really easy fix.

100% correct. Floating calipers use slide pins to equalize the piston force on each side of the rotor. When the bushings for the slide pins are worn out, you get exactly what you describe. Rattle on rough roads that stops when applying the brakes.

Might as well upgrade to the Maximum Motorsports Stainless Steel Brake Caliper sleeves. Search for "MMSSCS" under product search.

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