SOLVED!
I finally got to front rotors, pads and looking into the ABS sensor issue that was driving me bonkers on the highway... The issue I had was ABS check ran OK on start-up, no ABS lights/chimes driving anywhere around town. Only on the highway, after a couple of miles, the light/chime would come and go constantly. On my weekend commute of 30 miles each way, the chimes were driving me insane! Then they would go off and stay off, once I got off the highway and drove less than 50/55 MPH.
Potential suspect causes:
Bad wires/connections.
Bad sensor.
Bad hub.
Instead of cleaning and replacing the old sensor in the same hub or swapping positions with the problematic left sensor over to the right side to see if the issue follows or replacing the entire hub with a new one including a new sensor, I decided to try a new sensor first. Fewer steps and less chance of having to re-do hub and brake removals.
I bought NAPA brand ABS sensor (Echlin in this case) for $38. NAPA Part # UP 531158.
I got it on sale and had $5 in rewards points to use. Final total cost for the order was $28.90.
Hub was solid. It rotated easily and smoothly. It made no unusual groans or grinding noises. That was promising.
I pulled the old sensor out and inspected. There was a single shim under it, but the sensor looked like the tip was grinding into the reluctor ring in the hub. Kind of looked like the tip of the sensor was ground off and slightly curved. Maybe the last time the ABS light/chime came on, someone ordered an Amazon special or generic part that was just a hair too long. Not sure...
I sprayed down the reluctor wheel with BrakeKleen and blew it out with compressed air. That cleaned up the ring good. There was a very slight groove in the ring, probably from a sensor that was too long grinding into it... But, it didn't look too serious. I test fit the new sensor. It seemed like it made slight contact, so I re-used the single shim that was under the old sensor. Felt like it cleared perfectly. I put it in and completed the front brakes.
ABS test on start-up was OK. Things were off to a good start. No light/chime around town. Also a good sign. Real test was my usual weekend commute on the highway Saturday.
As of Sunday, I have driven 3 runs on the highway of 25 miles each. Highway aversion therapy is finally over!!! My sanity has been restored! No ABS lights or brain piercing chimes!!! I actually love driving my "new" Tahoe on the highway now. It just cruises along nice and quiet. These are fantastic vehicles and I am glad I got into one!
Thanks for all your support/advice! I managed to get off the hook pretty cheap and easy on this one. I am happy my Zurich scanner from Harbor Freight was able to narrow down the issue to the left front sensor. That saved me a lot of time trying to find the source of my problem and save me a lot of money by me not just replacing all the sensors to see what worked.
Thanks!
P.S.: Raybestos pads and rotors from our forum sponsor, RockAuto, for less than $100 shipped! Could not be beat. I normally go premium coated, but had to do a budget job this time. Similar basic pads and rotors were averaging about $200 locally.