Originally Posted by Android XTC
It is my understanding the USB connector is not at fault really. Its the solder points that crack off the Motherboard and cause this issue. Because of normal use (pushing in and pulling out of the cable) the solder that connects the Female USB port to the Motherboard cracks and causes a loose intermittent connection. IMO its the fault of HTC for not soldering the connections properly and or not designing the connector in a way to remove the stress off the solder pins. In most cases all that needs to be done is to have the USB port re soldered to the Motherboard to fix the issue. Now how long the new solder holds until it cracks again could be another story because of the poor design. You can be sure Sprint and HTC are well aware of this problem and to avoid having to replace and pay for a gazillion connector repairs or worse replacement handsets, they devised "the customer abuse story" its quite obvious to me.
As I understand it it, the problem lies in 'cold solder connections' which is a relatively common problem of poor assembly in electronics in general. Not really applicable in our case, however those subjected to repeated heating and coolling will suffer fatigue and stress cracks just due to those cycles. In our case physical stress from leverage is the real culprit. In these situations it is generally batch or line related and not all, or even most, units will suffer for this problem. Cold solder is easy to tell and sevice will readily identify if that is the case or abuse is to blame
If the joints are resoldered corrrectly the problem is eliminated except in the case of abuse which would be pretty clear by likely having physical damage to the port or the board.