Sounds like a loose connection from the screws inside the housing of the iron. It is a wee bit of a bugger to get INTO this iron, but with a little patience, and a screwdriver (phillips, the + one) you should be able to get to where the power cord connects to the terminals inside the iron. Loosen, and retighten the connection. If the wire seems 'worn', you may have to cut it back a bit and score off some of the plastic, and re-wire.
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