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I had the same problem. The repair took less than 15 min. I opened the bottom of the iron and discovered what appears to be a design flaw on the cord holder/fastener. The holder is wedged so tight that it pinched the cord wire almost in half. I removed the cord, cut it off at the pinched spot and reinstalled. I also put a small piece of rubber onto the part of the holder that is made onto the body of the iron. In addition, I rotated the fastener cap so that the smooth side of it is against the cord.