Ipod freezes during sync then error that it cant read file...

A little pre-info... I have owned a black 30gb 5th gen (video) Ipod for a couple of years now. I plug it in fine, my computer recognizes it fine, Itunes works fine with it... everything works great.
I just bought another Ipod off ebay that is exact as mine except white- auction states the Ipod works fine, seller has awesome feedback, etc.. I bought this for a gift for my sister for Christmas. It is second hand, so warranty is expired.
I plug it in the computer, and first tried to transfer some normal text data via explorer. I had put this same data on my own black Ipod with no issues, words fine. The white? Lo and behold I get that "Data Cycle Redundancy" error during copy. My experience is that that has always meant that the original file is messed up, not the destination its being copied too... but in this case I know the original file(s) were/are ok.
And the Ipod freezes. So I safely unplug, and try to hard reset it. It wouldnt for a bit, and I noticed the Ipod was rather warm (but this might be because it was frozen for several minutes with the backlight still on as well). Finally I get it to reset. Same stuff happens again, again its hard to reset.
So then I decide screw it, forget adding the stuff via explorer, Ill just try to get the music on my computer at least, over via Itunes, after I first restore the Ipod.
Itunes opens... recognizes the Ipod... I go to copy music, and it copies until it essentially 'freezes'. I tried many times - its not a bad file because the same file would copy the other times Id try. It would freeze on any random file, during the write process.
Then Itunes comes up with this error:
"the ipod cannot be synced. the required file cannot be found"
I dont think this is referring to my files trying to be copied, they werent deleted or moved from their location since importing into the Itunes library. Im wondering if theres a system type file on the Ipod that Itunes speaks to as it transfers...and when the Ipod freezes... hence it cant be found...
At the same time I get this error from Itunes, I get a Windows XP bubble pop up that says:
"Delayed Write Failed - Windows was unable to save all the data for the file x. The data has been lost. This error may be caused by a failure of your computer hardware or network connection. Please try to save this file elsewhere."
Now again, my computer/windows is NOT the issue. Its the Ipod.
All the advice I have searched says to fix things on my computer. That includes that Apple support page in regards to those errors - it points the finger at my USB ports, etc - and thats simply not the case. If it was, my other Ipod wouldnt be working either - nor would my flash drives.
Its the white Ipod.
I saw one site suggest to format the Ipod via Windows first, then do the Itunes restore, but the Ipod froze and Windows couldnt format.
I went into Device Manager and compared the two Ipod settings, both share the same settings. They are not set on 'enable write cache'.
I have tested the HD via Diagnostics, and the BL blinked after the test, showing the HD passed... so right now I can only think of three things... a bad logic board perhaps, or the Ipod system files are corrupt somehow no matter how many times I do the restore... should I revert to an older update; is that even possible. Or the HD is bad after all and its just being missed in the test.
So now... I need help. Am I missing something important? Is it a simple fix... a corrupt file thats freezing the Ipod somewhere - or did I get a bad Ipod from the seller.
Its so close to Christmas, if there was some simple fix(instead of it being a bad HD) I could fix it myself, Id rather do that than go through the hassle of returns/refunds. Not to mention, its always a gamble how the seller will react. Will they help, or say its not a problem on their end and try to screw me... then Ill have to go through Paypal for reimbursement and that takes 90 days at least...

I wish I had good news but all I have is information. I have access to 4 5th gen ipods. 2 black 30s and 1 white 30 and 1 black 80. The one white and one of the blacks work and have worked flawlessly for the past two years. The other black 30 and 80 started having the issue mentioned here some time after upgrading to iTunes 8. I tried to lowlevel format the iPod drive to fix any issues and that didn't cure the problem. I bought a MacBook a couple of months ago and restored my ipod to Mac format and low and behold it would accept files again! However it wouldn't let me fill the ipod beyond about halfway, this was on both ipods. Now the ipods have become slowly less and less fillable. Seems like syncing rather than putting the songs on manually seems to help, but again its getting worse all the time. (the two ipods that don't have any problems belong to my girls and the problem ones belong to my son and i) <- Grasping at straws I know, but my son and I are constantly changing the songs, playlists, videos and such.
When I bought my Mac the guys at the Apple store were shocked that I was having this problem and practically begged me to bring it in so they could see what it wrong with it. I will post an update when i do that.

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