i also just realized that i recently started using a tremor pack and it is a madcatz one!! i am gonna stop using the pack and the controller!! Thanks guys!
Ah, a tremor pack. That makes much more sense now. It's probably that, not the controller. I don't see how a bad gamesave would cause a resistor to blow like that.
That would make sense as a faulty tremor pack would be pulling more power from the system and causes the controller to cut out when you get hit. Have you just tried not using the tremor pack with the controller?