Do you leave the plug it connected in transport? Are you sure you haven't broken a pin in the tool connection? This does happen to Festools. . The negatives of the plug it..
However, I have noticed the newer cords have an updated plug it head, that looks like it puts a little less restriction/presure on the base of the pin inside the tool. The pin holes on the plug are beveled like a countersunk hole, in order to not touch and twist on the base of the pin in the tool and eventually snap it...
No idea when this change happened, just got a cord last month like it. My other cords are probably quite old. The new cord, or rather plug, also now has 4 recessed green tabs for disassembly, rather than the two tabs of old.