I've been having intermittent problems charging my PIP with my OEM EVSE for about the last month or so. Eventually I figured out that my EVSE must have a break in one of the wires at the point where the cable comes out of the EVSE "brick" on the side going to the J1772 connector. I found that I could only get it to work when I positioned the cable at a right angle to the brick in the direction of the top side of the brick. I used a 12" right angle shelf bracket to maintain that positioning, and used several feet of wide blue painter's tape to secure the bracket to the brick and cable (which worked flawlessly, by the way). Then I took it into my Toyota Service Dept. and explained the situation to them. Their "fix" was to remove the little rubber orange gasket from inside the J1772 that they said can get mis-positioned and make it difficult to insert the J1772 into the receptacle. Apparently there was a Service Bulletin published about it. So I had to go plug in the EVSE into my PIP and move the cord around to show them what the real problem was. Fortunately they had one in stock that they gave me. They said that it would have cost me about $1200 if it was out of warranty.....lucky me!
I have the exact same problem, broken wire inside the cable at the car side of the brick, probably one of the smaller signal wires. I can no longer bend it to the "sweet spot" to get it working again. Going in for service Wednesday, and will take a copy of this thread with me. I have the extended warranty, so it should be covered.
The day is not long off I will be completely in the dark when people talk. And yeah, I'm guilty of it too. Not so long back I'd say stuff like: "Hey, want to go to A&B to look at the CD's?".
