Freakenstein (can't spell his actual name) gets ripped apart by the Commando Elite. Brick Bazooka has his lower half torn off. Both are repaired, Bazooka to full functionality. Why, then, does Nick Nitro "die" (for lack of a better word) when his legs are shredded? Freakenstein had to have been more damaged than him, they couldn't even give him both arms!
The damage sustained by Brick and Freakenstein left their circuits 'open', and essentially harmless outside of the damaged systems. The mangling Nick got probably shorted out his circuitry instead, permanently ruining him.
What happened to the other Major Chip Hazards that should logically have been in that truck?
This also leads to some Fridge Horror - after all, what happened to any Gorgonites in that truck?
Or worse; All those weapons they show up with were initially just toys. Where would they have found a source of military grade parts to "upgrade" them?
How did nobody manage to realise during the development of the toys that they were dangerous? Yes I know the CEO forced them to rush it so they said there wouldn't be time for testing, but they must have done some testing just to make sure they worked.
It probably wasn't extensive testing. They probably did little more than test the voice activation and articulation before turning them off and pushing production. Most of the issues were from long term activation. It's kind of like testing a device for functionality but not thinking to test for continuous or repetitive use.