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I had an intermittent problem with "connection break" on my charger...I had charged LOTS of different batteries with all types of connectors previously over time.
I had made up a series of adaptors from the charger...+/- bullet plugs in the charger to Deans male...deans female to large...large to small. I'd just resort to whatever plug in the sequence that I needed for whatever battery.
When I had the odd connection break issue I couldn't figure it out...battery looked good, battery connectors looked good (I had just cut off the tamiya and put on a deans)...multimeter check on the batt was ok.
Turned out one of the connections on the charger's deans plug had come loose...probably from me pulling on it (I wish the plugs had a little pull loop on them). Not so loose as to fully disconnect...the shrink wrap was holding it connected (enough) in most positions...but when I hooked up in a certain position on the table I'd get a connection break. Quick resolder of the charger end and it was all good.
I've also had issues before with the wires just after the Deans corroding/breaking. On one of the last ones I saw the deans solder was good...but just behind it in the shielding the wiring was corroded and several strands were broken. A good tug and the remaining wires snapped. I suspect that water/etc had gotten in and corroded the wires. Not visible from the outside as it was sort of shrink wrapped and taped.
Another one I had was where a connector in a pack was loose. The shrinkwrap/packaging would sort of hold the connection...but there was a definite break in the pack if it was stressed the right way.
So...if it's a goofy electrical issue...go back to basics. Charger...battery...wiring harness. Personnaly I find it easier to bin a gremlin battery pack or to simply rewire a mechbox than it is to pin down a phantom electrical break.
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