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[Marks DTM Calib]

The problem is that the bond wire is steel.....hence soldering is very difficult and the pad onto which it must go is very small

Curious choice of material - but I guess Bosch had their reasons! I presume the wire can't be replaced with copper? (But that might upset the electronics if it's resistance is critical - although what's few pico ohms here or there between friends!! Plus it might increase the risk of heat damage to surrounding components.)
Or have you tried a corrosive flux like Bakers Fluid?

Steel is pretty much the standrad practive for bond wires and is resitance welded onto the pads

[GaryBC]

The problem is that the bond wire is steel.....hence soldering is very difficult and the pad onto which it must go is very small

Curious choice of material - but I guess Bosch had their reasons! I presume the wire can't be replaced with copper? (But that might upset the electronics if it's resistance is critical - although what's few pico ohms here or there between friends!! Plus it might increase the risk of heat damage to surrounding components.)
Or have you tried a corrosive flux like Bakers Fluid?

Steel is pretty much the standrad practive for bond wires and is resitance welded onto the pads

Presumably so as not to have to worry about heat damage to surrounding components during assembly. So is it the actual weld that fails? Or the adjacent conductor?

I'd love to get my hands on a busted ECU just so as to see (in the flesh, as it were) the problem!