Jim,
That's excellent information and thanks for answering. Glad to hear your wife is happy with her kit now too.
If I understand correctly Swytch sent you folks a new power pack replacement connector, plus new handlebar bracket/connector, PAS, and charger. Can you please confirm and if you're using all the new parts on your wife's bike?
I'm wondering if the new handlebar bracket might also be key to your success. I have swapped the power packs between my bike and my wife's bike and I still get see some issue with my own power pack on her bike even though it has been reliable on my own bike. It is not as bad as with her own power pack and handlebar bracket. So if this is all relates only to power pack connections I think the variation in tolerances of both the power pack connector and the handlebar connector/bracket are involved with our issue, though more from the power pack connector.
BTW, I'm keenly interested how your upgrades work out, especially the all-in-one PAS. The Swytch PAS sensor must sense the direction of magnet movement since it knows to ignore reverse spin of the crank. I guess it's a Hall-effect device?
Thanks again,
Chris