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Spent 11 hours tracking a bad pin connection, it was a cracked backshell the whole time
Got called out to a regional jet in Nashville for an intermittent flap position fault. Pulled the cannon plug on the actuator, checked continuity on all 17 pins, everything passed cold. Re-seated it, fault cleared for one cycle, then came back. Did this dance three times across two days before I finally put a jeweler's loupe on the backshell and saw a hairline crack right where the strain relief meets the shell. Vibration was making the pin wiggle just enough to drop signal. Swapped the whole connector assembly, took 40 minutes. That was 11 total hours spread over three visits for something I could've caught day one if I'd looked closer before testing. Anyone else find themselves trusting the multimeter over their own eyes too much?
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