I submitted yesterday the online form for the recall, today I already received a shipping label via email (for shipping with UPS - standard shipping, not express shipping). I will send it away as soon as possible and I will see how long it will take to receive a replacement product.
Are there noticeable differences between the old and the new product?
You are right, this problem could also exist because of a faulty product (or cord / strain relief) design, but then they have a problem with the quality assurance regarding the desing execution or regarding the testing of the product in real-life conditions. I mean, when a product is designed, this is not made by only one employee but by whole teams of employees, the testing of the products and the development of the product testing methods is usually also made by whole teams. So critical problems should have been noticed theoretically right away, or at least in the first 1-2 years after the product launch. Maybe it was something that they did notice but they did not consider it as something critical, or they considered it as being an acceptable thing that can normally happen after x years of use - they theoretically also sell replacement cords if your cord gets damaged, but I think they were thinking about other types of (mechanical) damages, they did not expect that you could also have an "intermittent" problem that can pass the self-test. But it also could be that they just wanted to lower the manufacturing costs and save a few cents and hoped that there will be no problems with the products - like Weller did with the soldering stations by not installing a fuse on the primary side of the transformers - no one noticed it for many many years, only after Dave made a video about that, everybody started to go crazy about it. Only Fluke could give us an answer to this but they probably won't say anything about it...
The original description of the safety issue:
"It has been determined that certain Recalled Testers may experience premature failure of the interconnecting cable under cyclical bending stress. Recent experiments conducted by Fluke have shown a wide distribution in the number of cycles to failure exhibited by the Recalled Testers, meaning that certain Recalled Testers are subject to failure earlier than expected, leading to a useful life for certain of them that Fluke considers unacceptable.
Further, the cable may fail in an intermittent fashion where, depending on the cable flex orientation, it is possible for a Recalled Tester to pass a self check continuity test or validation on a known voltage source, while subsequent tests may display a false negative.
[...] Our R&D, Quality, and Safety teams have qualified a new cable to be used in the T-Pole Testers, which makes them more robust. In addition, we have now implemented additional improvements to the strain relief complementing the cable strength. Testing of these new changes has shown improvements in cable cycle performance."
When I purchased this product many years ago, Fluke advertised this product as a very reliable product with "a heavy duty molded case, a thicker cord with wear indicator, sturdy battery case, and well-fitting and durable probe protector". So I naturally expected that they test the cords from each batch accordingly, simulating many different wear and tear scenarios that normally occur in real-life usage (including cyclical bending stress). But now I ask myself what did go wrong at Fluke, in the case that this problem was noticed only now and not sooner? I also wonder what will Fluke do with the returned products? Maybe they replace the cords with the new ones and resell them as refurbished products?