Break pedal sensor works off ohm reading as the brake pedal is being pushed. So pedal at rest, Pedal should have a fix ohm reading on a given value, and brake pedal pushed should have another ohm reading isntead.

Hence since different brake senors have different ohm reading on the arm position of the sensor, its the reason that you have do a BPP relearn so the car learns the ohm reading of the pedal at rest, then the pedal pushed down.

So sounds like the brake pedal sensor just needs to be replaced.
As for to figure this out if the BPP sensor is going out, Tech II go to EBCM module, data, and make a note of the BPP sensor reading at pedal at rest, then with it pushed all the way down, and then when the car has to go back in for another BPP relearn, if the ohm reading are different, the brake pedal position sensor is going south.

As for the BPP sensor, it only a $25 part, but no joy replacing it since it up in the lower dash on the brake pedal bracket and you play contortionist on your back.side jammed in the floor space in front of the seat to replace it. Also since the Fork piece has to stay spring loaded on the pedal Stud (don't forget to grease the inside of fork and stud to slow down wear), the bolts that hold it in place as way too long, so you have to hold it in place with one hand, as your fumbling with the bolts to get them installed and tighten as well.
Note, the only way to pull this off since your jammed in like a sardine in a can, put the bolts in your lips with your mouth closed, so you can get to them with spare hand not holding the sensor it place, and don't swallow one of the bolts. Or the other trick that works, tape the bolts to your forehead, and slip the bolt off one by one as needed, or have a helper hand you the bolts as needed if you do have a helper to begin with.

P.s. the lower dash valance piece comes off easly since it just retained in place via few bolts and snap type pieces, and you need to remove it give you access to the bottom of the dash in the first place.

Also, when you go to do the BPP relearn, don't go hold wild on the brake pedal push trying to max it out to the floor. Just push the pedal down like you would normally during a break stop, and set the press position (sensor ohm reading) to that. Hence some tech will press the pedal way down too far trying to get it to max out on the bottom that your never going to push the pedal to in the first place, and when you are trying to start the car, you may not have the pedal down far enough to for the car to see the needed BPP ohm reading instead.

 

 

Hello I had something similar and the dealer found a recall notice that would cause the service active handling system error to pop. When you said mechanic did it happen to be a GM mechanic that had access to the recall information? Here is what I found:GM IS RECALLING CERTAIN MODEL YEAR 2005 AND 2006 CHEVROLET CORVETTE PASSENGER CARS MANUFACTURED BETWEEN MARCH 2004 AND JANUARY 2006 EQUIPPED WITH A TILT AND TELESCOPING STEERING COLUMN (RPO N37). IN RARE CASES, REPEATED MOVEMENT OF THE STEERING COLUMN MAY CAUSE A SIGNAL INTERRUPTION WITHIN THE COLUMN. IF THIS OCCURS, THE MESSAGE, "SERVICE ACTIVE HANDLING SYSTEM" WILL APPEAR IN THE DRIVER INFORMATION CENTER, AND ONE OR MORE OF THE BRAKES MAY APPLY, POSSIBLY CAUSING THE VEHICLE TO PULL TO THE RIGHT OR LEFT.