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Old 6 Days Ago   #16
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Re: replacing wire harness for boot/hatch

From memory the 500ís harness exits the body and bends and then itís the bent bit that also gets twisted by the movement of the hatch. This is a major stress point. I rather suspect that to make it 100% reliable would have required a change to a pressed body part which is tens/hundreds of thousands of pounds of cost in tooling.
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Old 6 Days Ago   #17
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Re: replacing wire harness for boot/hatch

Quote Originally Posted by 306maxi View Post
From memory the 500’s harness exits the body and bends and then it’s the bent bit that also gets twisted by the movement of the hatch. This is a major stress point. I rather suspect that to make it 100% reliable would have required a change to a pressed body part which is tens/hundreds of thousands of pounds of cost in tooling.





I'd forgotten about the twisting; it's the combination of repetitive bending and torsional stresses on the cable that precipitates early failure. The door wiring only has to bend - there's no twisting involved.

And you're right; fixing this properly would require a fundamental change to the way the wiring routes through the hatch and this would not be cheap. It's a shame; the Panda doesn't have this problem, which just goes to show that whenever you make even a relatively small change to a design that works, there's always the risk of introducing a new problem that wasn't there before.

The Panda door handles are another example; they may not be as pretty as the 500 design, but they do generally stay attached to the car for the whole of its natuiral life.

Reengineering the Panda 169 into the 500 really is a triumph of form over function. I guess that's what sells cars in the short term, but I know which one of the two I'd buy again.
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Old 5 Days Ago   #18
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Re: replacing wire harness for boot/hatch

I would look at replacing the cables with a good quality silicone wire with a high strand count, ultra flexible and durable. Can be picked up online by the metre relatively cheap.
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Old 2 Days Ago   #19
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Re: replacing wire harness for boot/hatch

the repair kit i found on ebay is made in germany
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Old 2 Days Ago   #20
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Re: replacing wire harness for boot/hatch

Quote Originally Posted by birdy2005 View Post
the repair kit i found on ebay is made in germany
Most of them seem to be made there, though they don't state what type of cable is used, but it will fix it and may work for the rest of the time you have the car?
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