At this stage, I would recommend a drastic step. Next time you have a lot of time, take it apart from the dash. Check any and all crimps for a loose connection. Insulate any electrical junction (RCA connectors wrapped in electrical tape, etc.). Wrap the sled itself with electrical tape. Verify that the wires in the harness are all secure. You certainly have a loose contact somewhere...
_________________________
Paul Grzelak
200GB with 48MB RAM, Illuminated Buttons and Digital Outputs