Here's a standard trick I used whenever opening up and servicing a transformer for any reason. Pinch a tight loop of the wire between the thumb and forefinger. Completely close the wire loop under as much pressure as you can with you thumb and forefinger. Open the loop up and closely examine the insulation on the wire. If you can see a fatigue break anywhere in the wire, replace the wire and plug completely. Replace it with the same strain relief knot that was in the original wire. 99 times out of 100, the problem is in aged wire insulation that easily cracks open and exposes the wires themselves to the case or to each other, resulting in the sparks and/or electric shock.
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