IPod Drive Problems

I have looked before asking, so I feel safe posting this brainteaser.
I have had my IPod for over a year and a half without any problems up until a few weeks ago. I forgot my charger at home and used my friends Apple to fill my battery. The problem was his comp automatically formated my IPod over to mac settings. No problem I thought to myself and went home to restore it to factory settings. When I finished restoring I went to reload all my music back onto the IPod. This is where the problems begin.
I'm using an older model IPod, 15gb with the 4 buttons and the scroll btw. When the IPod reaches the 1.24 mark an error message pops up saying "The drive is not ready for use, its door may be open. Please check drive \device\harddisk2\DR4 and make sure that a dirk is inserted and that the drive door is closed" and I have 3 options which are Cancel, Try Again and Continue. They all result in ITunes freezing up until I unplug my IPod.
I have tried the "5 R's" many times with no luck. I have also tried it on another friends PC with no luck. I was sure this was a hardware issue until I spoke to apple customer service, where the helpful man gave me a hint saying that it wasnt hardwear issue and that I could do something else. As we all know though you have to pay 60 dollars to find out what that something is.
So thats the problem any help would really be liked. Wierd issue that I havent been able to figure out so please ladies and gents what are your thoughts?

First things first the spinning beach ball is usually an indication that Search is going nuts.
Turn off Search entire Library by clicking on the downward pointing arrow to the right of the Magnisying glass and untick Search entire library.
Is your music still in iTunes on your new hard drive or is it only on your ipod?
If it is in your itunes then you should be able to plug in the iPod and uncheck Manually Manage music and sync
If the music is only on the ipod connect up as above click on the device and Drag all the music from your device to the library. then you can uncheck manually manage music and sync as normal

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    [Zevoneer's detailed instructions on getting music off an iPod|http://discussions.apple.com/message.jspa?messageID=9053179#9053179]
    [Wired's How To: Get Your Music Off of Your iPod|http://howto.wired.com/wiki/GetYour_Music_Off_of_YouriPod]
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  • Solution for some iPod/iTunes problems...

    If you are having one or more of the following problems, Windows may be confusing iPod with a network drive or hard drive and may exhibit strange behavior, like:
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    -The iPod setup assistant appears in iTunes everytime the iPod is connected.
    -iTunes displays the "iTunes has detected an iPod in recovery mode- use iTunes to restore" message even after the iPod has been restored.
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    -Go to Disk Management
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    -Use the drop-down box to select a new drive letter. Make sure to use a drive letter that is not already assigned to a network drive. The drop-down menu will display all letters that are not assigned to a physical drive, but network drives will stil be listed so be careful. If you arent sure, add a new drive and pick your own letter, something way down the list is best since common drives are A, B, C, D, etc.
    -click OK
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    -Restart computer
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