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    Thread: Broken Sleeve on Electrical Harness leading to Trunk Lid - How to fix? [TOC, Photos done]

    1. Senior Member PanEuropean's Avatar
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      07-05-2011 01:52 PM #126
      Jay:

      Be very careful not to accidentally mix up two wires in the harness that both have the same colour coding. This is easy to do, and difficult to troubleshoot later.

      Michael

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      07-05-2011 02:10 PM #127
      Yes, Michael, I am very aware of this thanks to your great post. Is there a way to know which is which from the get go or do you just take your 50% probability of getting it right and switch them if you get it wrong? Thanks for the reply...Jay

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      07-05-2011 10:13 PM #128
      Quote Originally Posted by chillson View Post
      Damon, thanks for the reply. I hope to get the harness this week. I am not sure if I should complete the repair myself or let my non-vw shop do the work. You state that the procedure is quite detailed and specific. Where can I find this info? I didn't see any vw specs in the link. Do the specs instruct as to what needs to be disconnected (battery?) or anything else to protect the electrical system? Any thoughts or advice is much appreciated. Thanks...Jay
      I had mine replaced under warranty but gave the dealer a lot of information I gathered and printed. I'll have to see if I can find it. As I recall, they did have an issue getting the correct part.

      Damon

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      07-07-2011 12:32 PM #129
      Michael,

      I saw in FAQ that there is a 37 page document entitled "Wiring Harness Inspection & Repair" that you had attached in 2 parts. Neither part is now available on the post. Is this document still available? I would love to have it before starting my repair. Please let me know. Thanks...Jay

    5. Senior Member PanEuropean's Avatar
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      07-08-2011 02:06 AM #130
      Hi Jay:

      Here you go - it's attached below.

      Michael

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      07-08-2011 11:39 AM #131
      Michael,

      Thanks so much for the quick reply. I haven't read through the docs yet but I will let everyone know how the wiring harness repair works out for me. Thanks again...Jay

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      08-09-2011 11:09 PM #132
      So I ordered the wiring harness repair kit in early July from 1stvwparts.com. I was told it was one of only nine units available in the U.S. About a week and a half later, I received the unit but one of the plastic flanges on the cartridge that attaches to the trunk was broken off. 1stvwparts.com told me to send back the unit and they would order me another. This time there were only four units available in the States. Another week and a half and finally I have the part in perfect condition. Zeb at 1stvwparts.com was great to work with and they really helped me out (no hassle about returning the broken part for exchange).

      Last week my shop (non-VW) repaired the harness free of charge. When I dropped off my car (along with the new replacement harness), I sat down with the service manager and showed him this thread, 2 VW wiring harness repair tutorials, and even wrote a message about the two wires woth the same color code. They did a great job. The trunk cover and plastic parts were put back with excellent fit and finish (can't tell there was any work done) and the new sleeve with virgin mesh looks brand new. My unit does have the reinforced plastic neck above the ball joint (like in Michael's pictures above). I am now waiting for the back glass to arrive from Germany before I take my car back for them to complete the job.

      Moral of the story: I am very lucky to have such a good relationship with this shop. The harness was separated but still reparable when I took it in for a minor repair. They damaged the sleeve further and broke the rear window by opening and shutting the trunk against my instructions. To replace both the harness and back glass free of charge (including reimbursing me for the cost of the harness) is going above and beyond great customer service. I have been going there for over 13 years.

      Imporatant to consider: If the info I received from 1stvwparts.com is true, there are only 3 wiring harness repair kits (for manual lift trunks) available in the U.S. If any of you think you are going to have to undergo this repair, you may want to get the part while you still can (if it's not already too late).

      One last question: Is there any reason I shoudn't spray the mesh-covered sleeve with WD-40 to help reduce friction? Is there a better lubricant for this?

      Sorry for the long post but much thanks to many of you who helped me along the way. If not for this forum, I never would have known about the possibilty of cracked rear glass and I would have broken mine for sure. I would guess conservatively that the above repairs (wiring harness and rear glass replacement) would have cost me a combined $3000. Thanks again...Jay

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      08-10-2011 12:09 AM #133
      I would refrain from using any petroleum based lubricant on the plastic. It may attack the plastic. I use silicone based detail spray often to make the whole thing slick.

      Damon.

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      08-10-2011 08:57 AM #134
      On mine, the rigid tube came out of the spherical bottom joint and began to distress the wiring there. A few months of giving it a tug each time the boot closed was ok but annoying. eventually a wire did break (LH inner tail lamp). I spent some of a Saturday morning taking the trim off the bootlid and having a good look and a think.

      In the end I removed and dismantled the bootlid cassette assembly and cut/sectioned off the rigid tube. This liberated about 2 feet of harness that I double bound with electrician's tape after soldering and heat-shrink protecting the broken wire. Inside the cassette there is a serpentine guideway for the harness. There is one small section about 1 inch long (just by the thumb in post #112) that can be trimmed out to allow a straight run for the harness to then go straight through, using the cassette merely as a guide to keep the cable run stable inside the bootlid trim, stopping it tangling and ensuring it exits the trim in the same place as originally. The difference now is that the cable is more than long enough to take care of itself when the boot operates. The cable movement is such that there is little chance of future fatigue due to excessive movement. My only regret is that I only had red tape on the day, but that's easy!

      It is a pity that some idiot designed such an utterly stupid (but almost clever) method of getting power to the boot electrics. Its not even as if it looks good from new; beautiful engineered hinges, hidden edges, subtle mechanism and fine trim covers. And a stupid black prong to break up the lines. Why not just run it conventionally or even use sprung contacts like on the Q7?

      And why have a premium car with a sat nav that won't take post codes!!

      Other than those two issues, a great car!
      Last edited by gartracescort; 08-10-2011 at 09:06 AM.

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      08-10-2011 09:00 AM #135
      Quote Originally Posted by dlouie View Post
      I would refrain from using any petroleum based lubricant on the plastic. It may attack the plastic. I use silicone based detail spray often to make the whole thing slick.

      Damon.
      I do the same, using silicone spray for the same reasons. So far mine looks and functions like new. However, I am VERY careful when I close my trunk and try making sure that no one else touches it.

      I think this is another of those significant but generally preventable repairs on the Phaeton.

      Jim X

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      08-10-2011 09:12 AM #136
      On mine, the rigid tube came out of the spherical bottom joint and began to distress the wiring there. A few months of giving it a tug each time the boot closed was ok but annoying. eventually a wire did break (LH inner tail lamp). I spent some of a Saturday morning taking the trim off the bootlid and having a good look and a think.

      In the end I removed and dismantled the bootlid cassette assembly and cut/sectioned off the rigid tube. This liberated about 2 feet of harness that I double bound with electrician's tape after soldering and heat-shrink protecting the broken wire. Inside the cassette there is a serpentine guideway for the harness. There is one small section about 1 inch long (by the thumb in post #112) that can be trimmed out to allow a straight run for the harness to then go straight through, using the cassette merely as a guide to keep the cable run stable inside the bootlid trim, stopping it tangling and ensuring it exits the trim in the same place as originally. The difference now is that the cable is more than long enough to take care of itself when the boot operates. The cable movement is such that there is little chance of future fatigue due to excessive movement. My only regret is that I only had red tape on the day, but that's easy!

      It is a pity that some idiot designed such an utterly stupid (but almost clever) method of getting power to the boot electrics. Its not even as if it looks good from new; beautiful engineered hinges, hidden edges, subtle mechanism and fine trim covers. And a stupid black prong to break up the lines. Why not just run it conventionally or even use sprung contacts like on the Q7?

      And why have a premium car with a sat nav that won't take post codes!!

      Other than those two issues, a great car!

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      08-10-2011 10:26 AM #137
      ...
      And why have a premium car with a sat nav that won't take post codes!!
      ...
      I don't know about Germany but in France, a post code corresponds to a town, or a group of hamlets or smaller towns (in fact, the postcode is the code of the main post office of the town that then redistributes the mail to smaller postoffices that then redistribute the mail to residents).

      In Paris, there as are many postcodes as there are "quarters", i.e. only 20, with as many as 30k inhabitants for the 75020 postcode.

      All this to say that this is different from England, where a postcode is more or less specific to a block.

      In France, there would be no point in typing in a postcode as it would get you to the town (67000 = Strasbourg).

      If this postcode system is comparable in Germany and the GPS system was designed in Germany, nobody would have seen the point of putting a postcode as a direction.

      P.
      Last edited by Zaphh; 08-10-2011 at 10:40 AM.

    13. Member EnglishPhaeton's Avatar
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      08-10-2011 11:01 AM #138
      Quote Originally Posted by Zaphh View Post
      I don't know about Germany but in France, a post code corresponds to a town, or a group of hamlets or smaller towns (in fact, the postcode is the code of the main post office of the town that then redistributes the mail to smaller postoffices that then redistribute the mail to residents).

      In Paris, there as are many postcodes as there are "quarters", i.e. only 20, with as many as 30k inhabitants for the 75020 postcode.

      All this to say that this is different from England, where a postcode is more or less specific to a block.

      In France, there would be no point in typing in a postcode as it would get you to the town (67000 = Strasbourg).

      If this postcode system is comparable in Germany and the GPS system was designed in Germany, nobody would have seen the point of putting a postcode as a direction.

      P.

      Pierre,

      never even thought of that!
      Our postcode in France is 9500, small town called Mirepoix. I am guessing you could find us by asking someone on arrival!!! Defeats the object somewhat!
      However our UK post code would indicate the Town, Street, and odd or even house number!

      Stu

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      08-10-2011 11:12 AM #139
      Quote Originally Posted by gartracescort View Post
      This liberated about 2 feet of harness that I double bound with electrician's tape after soldering and heat-shrink protecting the broken wire.
      Note that VW does not recommend soldering as an acceptable repair for wiring. Please see Michael's posting above with attached documents.

      Damon

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      08-10-2011 12:17 PM #140
      Quote Originally Posted by EnglishPhaeton View Post
      Pierre,

      never even thought of that!
      Our postcode in France is 9500, small town called Mirepoix. I am guessing you could find us by asking someone on arrival!!! Defeats the object somewhat!
      However our UK post code would indicate the Town, Street, and odd or even house number!

      Stu
      Err...,

      I'm afraid you didn't get what I said.

      I have the pleasure to inform you that your postcode 9500 corresponds to no less than 22 towns or hamlets !!! (cf. below).

      So I have no doubt that in Mirepoix, everyone knows about that English guy with his strange VW, but if you gave me your postcode only (9500), how would I know I would need to go to Mirepoix to have the pleasure to meet you ?

      09500 is the postcode of the following towns:

      09500 BESSET
      09500 CAMON
      09500 CAZALS DES BAYLES
      09500 COUTENS
      09500 LA BASTIDE DE BOUSIGNAC
      09500 LAGARDE
      09500 LAPENNE
      09500 MALEGOUDE
      09500 MANSES
      09500 MIREPOIX
      09500 MOULIN NEUF
      09500 RIEUCROS
      09500 ROUMENGOUX
      09500 ST FELIX DE TOURNEGAT
      09500 ST JULIEN DE GRAS CAPOU
      09500 ST QUENTIN LA TOUR
      09500 STE FOI
      09500 TEILHET
      09500 TOURTROL
      09500 TROYE D ARIEGE
      09500 VALS
      09500 VIVIES

      Btw, mirepoix is the name of a famous French side dish http://fr.wikipedia.org/wiki/Mirepoix_%28cuisine%29

      It would be interesting to know if the mirepoix mix of vegetables originated from Mirepoix.

      Could you ask around ?

      P.

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      08-10-2011 01:02 PM #141
      Quote Originally Posted by Zaphh View Post
      Err...,

      I'm afraid you didn't get what I said.


      It would be interesting to know if the mirepoix mix of vegetables originated from Mirepoix.

      Could you ask around ?

      P.
      Pierre,

      I didn't realise we shared the code postal with quite so many neighbours!! In answer to the mixed veg dish it has no apparent connection to the town of Mirepoix.
      I asked many years previously!

      Stu

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      08-10-2011 05:27 PM #142
      Quote Originally Posted by Zaphh View Post
      Btw, mirepoix is the name of a famous French side dish
      It would be interesting to know if the mirepoix mix of vegetables originated from Mirepoix.
      Hi Pierre,

      This dish was given that name by the duke of Lévis-Mirepoix, a guy with the name Gaston Pierre de Lévi. Actually, his cook invented it, who happened to be a Dutch guy, captured by the inquisition during his summer holiday. He was released on the condition that he would create a famous dish for king Louis XVI


      The truth is over here: http://en.wikipedia.org/wiki/Mirepoix_%28cuisine%29, with (strange, but true) a lot more information than the French Wiki.

      Regards,

      Willem

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      08-10-2011 10:14 PM #143
      Quote Originally Posted by WillemBal View Post
      Hi Pierre,

      This dish was given that name by the duke of Lévis-Mirepoix,...
      Which takes us back to the original question: was the "Mirepoix" of the duke of Mirepoix the small town currently occupied by the English ?

      P.

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      08-11-2011 02:59 AM #144
      Quote Originally Posted by Zaphh View Post
      Which takes us back to the original question: was the "Mirepoix" of the duke of Mirepoix the small town currently occupied by the English ?

      P.
      Pierre,

      short answer is yes, although the (VERY) mediocre Château of the Levis family still exists, albeit in a poor state these days, the most famous (and therefore most celebrated) member of the Levis dynasty is Guy.
      Very little info on him doing a quick search of Wiki, although I have read quite a bit about his exploits. He was heavily involved during the Albigensian Crusade, and was allied eventually with Simon De Montforts armies in their extermination of the Cathars.
      If you are interested in a very absorbing book I can thoroughly recommend the "Massacre at Montsegur" Written by a German woman whose name escapes me, but well worth a few hours!

      Stu

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      08-11-2011 10:32 AM #145
      No, the answer that a "mirepoix" comes from the Duke of Mirepoix's cook in Mirepoix is perfect enough for me. One last question: is it standard for local restaurants to serve meat with a "mirepoix de légumes" ?
      It is not obvious that they should, because cooking a good mirepoix with matching gravy takes time (more than throwing a bag of frozen chips into rancid oil (yuck !)).

      P.

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      08-11-2011 12:55 PM #146
      Solution based focus or "Famous cooks of France for 500" ?

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      08-11-2011 02:20 PM #147
      Quote Originally Posted by dlouie View Post
      Note that VW does not recommend soldering as an acceptable repair for wiring. Please see Michael's posting above with attached documents.

      Damon
      Given a, the cost of a new part, b, the lousy design and c, the minimal current for a few LEDs.....I'll risk it!

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      08-12-2011 07:38 AM #148
      Quote Originally Posted by Zaphh View Post
      No, the answer that a "mirepoix" comes from the Duke of Mirepoix's cook in Mirepoix is perfect enough for me. One last question: is it standard for local restaurants to serve meat with a "mirepoix de légumes" ?
      It is not obvious that they should, because cooking a good mirepoix with matching gravy takes time (more than throwing a bag of frozen chips into rancid oil (yuck !)).

      P.
      Pierre,

      we are talking Ariege here! My children first encountered the local "mirepoix" at school, they still refer to it as "left-overs"!!

      Stu

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      08-12-2011 10:53 AM #149
      As much as (as a Phaeton owner) you certainly understand the difference between a Phaeton and other cars that may look more sexy at first glance, but lack the refinement of the Phaeton, you must understand the mission you have to educate your kids and (having the blessing of living in a wonderful part of France) teach them the difference between junk food and the much revered "mirepoix de légumes," which was invented where they live, and which is so exquisite with, say, "un gigot de 7 heures" http://www.meilleurduchef.com/cgi/md...eures_ill.html

      Another activity you should indulge in and become a master of while you are there: http://webtv.ac-versailles.fr/restau...ation_articles
      Last edited by Zaphh; 08-12-2011 at 12:28 PM.

    25. Member EnglishPhaeton's Avatar
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      08-12-2011 01:36 PM #150
      Quote Originally Posted by Zaphh View Post
      As much as (as a Phaeton owner) you certainly understand the difference between a Phaeton and other cars that may look more sexy at first glance, but lack the refinement of the Phaeton, you must understand the mission you have to educate your kids and (having the blessing of living in a wonderful part of France) teach them the difference between junk food and the much revered "mirepoix de légumes," which was invented where they live, and which is so exquisite with, say, "un gigot de 7 heures" http://www.meilleurduchef.com/cgi/md...eures_ill.html

      Another activity you should indulge in and become a master of while you are there: http://webtv.ac-versailles.fr/restau...ation_articles
      Unfortunately or fortunately depending on the day, our children have now matured to young adulthood. They do not and have very seldomly partaken of junk (fast) food, even whilst in France (where MacDonald's is noticeably better to the UK outlets). I admit that the leg of lamb cooked very slowly is a family favourite but not, alas the mirepoix (mixed veg in stock).
      Both of our children (but not my wife or myself) particularly enjoy Cassoulet, especially when visiting friends in Revel, just outside of Castelnaudary (The canal boat hire there is both good and inexpensive, especially compared to Carcassonne)
      I feel however that we have perhaps hijacked this thread. Maybe we should start a new one comparing Phaeton owners favourite dishes/wines/restaurants?
      You go first Pierre, I have no doubt reading previous posts on your gastronomic delights that an intriguing thread would develop.

      Stu

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