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The controller sees a stall by the encoder feedback stopping. If the motor is still turning and you get a stall fault, the controller isnt seeing the encoder signal. Since its doing it on both motors, the cable might have a bad connection on the encoder wires. I cant work out exactly whats going on when you swap only one end of the cables, try swapping the 2 cables round totally and see what happens.
I dont get the "working sometimes" part unless theres an intermittent connection/wire. If the problem was balance/gears and you are playing with these during testing, I would have expected a "lag" error sometimes, (especially just before a stall), ie not a total stall, but enough drag for the controller to see the motor not going as fast as expected, this is probably not a connection/wire fault. If you get lag and stall faults, its probably mechanical.
If you only get stall faults, get your mutimeter out and compare the pin to pin connections end to end on both cables and wiggle them while your doing it. Of course any difference bettween the 2 is bad.
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