I've encountered a few problems with ED-E. First, when I realized how fragile he is, I made him wait for me in Good Springs while I explored. When I encountered the first catch-phrase in Novac, he wasn't with me, but I was still told that I received a quest, and apparently he said something that I completely missed. Is it possible to put whatever he says in the Notes section for future reference? He's said nothing since then, despite exploring through Helios, Boulder and elsewhere. I'm afraid the quest script might be broken, and I'd hate to have to FAQ this quest line.
After that, I made sure he was with me at all times. Now he has vanished altogether, although the engine treats him as still alive-- because I still have his perk, his quest, and NPCs keep saying "Nice robot," to me. He disappeared in the Mines in the NorthWest of the map, the one with Lakelurks in it. He was with me until I went swimming and had to fight several lakelurks after jumping out of the water: the water with the supermutant corpse in it with the Multiplas gun.
When I left the mines, I realized he wasn't with me. I've gone back inside, searched everywhere I can find, and he's not there, and there are no green pips on my compass except for Boone, who is also with me. I'm in a bind, because playing hardcoe mode, I mainly use the autosave. My last savegame is hours before (not a huge deal, but not very fun either.)
Was this caused by a pathing issue? Did ED-E fall through the world? Did he drown, die, and the engine not know how to treat it? Is he still with me but somehow phased into another dimension?
Please look into this for future patching potential, and thanks for an otherwise exemplary and amazingly novel experience.