This will sound like a strange kind of comfort for your problem cord!...
I have a Canon OC-E2 cord (purchased new, now about 7 yrs. old) for my 40D and Metz 54MZ. Randomly the cord will lose connectivity between the flash and camera...the flash and camera still communicate for the flash to choose ETTL mode (over TTL mode), it will continue to trigger, but the flash will overexpose by outputting full power. This happens much more if the camera is in Portrait orientation, but it does happen in Landscape orientation once in a while.
So I bought a new Canon OC-E3 cord, thinking the OC-E2 had gone bad. Same problem.
So I obtained two different aftermarket new cords thru POTN's member, FlashZebra. Same problem.
FlashZebra very nicely took back the cords, since they did not fix my problem. And I sold the OC-E3 on POTN since even a newer model Canon genuine cord had the same issue!!! But the problem NEVER occurs when the flash is mounted directly on the camera hotshoe!
Based upon the fact that many others have suffered similar issues even with Canon cords, I lay blame on some aspect of the fundamental Canon design of flash communication...why else would flash work correctly when directly on the hotshoe, but not work reliably even with a Canon cord?! Some folks have even asked Canon, but they get a non-answer.