Hello Mike,
This might be benign info, but when you mentioned that the front brake sensor is "intact," did you get a chance to actually remove the assembly to look at the sensor tip's CONTACT END (the part that would actually touch the rotor upon pad wear)? The reason being that as the sensor wears down over repeated brake changes, the wire enclosed/hidden inside the tip will become visible. Repeated brake changes and/or continuous wear on this now exposed wire will ultimately break the brake wire and create an open loop, thus triggering the brake light. It's very easy to miss, and I've missed it, only to have to remove the wheel and fix the connection (this can sometimes be done with solder and scrap wire to make the open loop become "closed." The important point here is that the actual tip end needs to be looked at closely by removing the caliper/pad assembly away from the rotor. It simply can't be done by an external visual inspection because although the sensor may look "intact," the tip's end may indeed have a broken/worn-out wire, which can only be diagnosed by removal of the assembly to look at the actual contact point. If you are looking at the sensor's end and see two separate wire ends (perpendicular) staring at you (like eyes in a carbon block), you'd have an "open-loop." All of this wouldn't matter or likely be of help if your sensor is brand new. FWIW, I hope this helps...please let us know what you found. BoL, /very
