Looking at the TSB and recall for this they don't actually replace anything, just add a spacer and some grease. I suspect that it recurs because the wires are corroding inside the crimped area inside of the connector body itself, or inside the wires between the brake pedal position sensor and the body control module. However neither the TSB nor recall replace the wiring section which is probably the root cause of the problem.
The system on the 04 and up are different than the earlier cars. Up until late 03 they used a simple on/off switch. On the 04 and up they used what is basically a potentiometer that sends a variable voltage signal to the BCM instead of just on or off. Almost the same as the gas pedal does to control the throttle. They did this to enable the airbags and ABS as well as traction control to determine how hard the brakes are being applied not just if they are.
As to a repair. I would try escalating the issue up the line to GM directly 1-800-222-1020. Tell them that the dealer has done the recall and it didn't work, as well as the other repair attempts and that you are scared to drive it because of this issue. See what they are willing to do about it.
The other option would be to replace the wiring between the BCM and the brake position sensor by removing the existing connection pins at both ends and replacing them with new. The recall says to check the pin fitment and repair as required, it is more likely that they apply the grease and spacer, stuff it back together and call it done. The repair may work on cars that don't have a bad problem, but if it is corroded or the connections are already damaged I doubt it would do much. Replacement with new connector pins and wire should work as you have had the other repairs work temporarily. Perhaps the mechanic you know could do that.
Monday, January 6th, 2020 AT 12:24 PM
(Merged)
