Ipod mini won't write past certain limit

I woke up this morning to the sad folder face on my iPod mini. After a reset, it was still a sad mini, so I did what I thought necessary: I restored it with updater software. Now, it connects ok, and what music I can put on it plays fine. The problem is that I can't put more than about 1.15 GB of music onto the mini. After that, iTunes and the mini both freeze, and my only recourse is to unplug it, ignoring the warning about not doing that, and resetting the mini.
I have tried to so a secure erase of the free space using disk utility, and it freezes at about 15% of the progress bar, right where I'd expect based on my writing issues.
Anybody encountered this and solved it? My iPod is no longer under AppleCare, so regardless of whether or not it's my fault (I'm not ready to admit any blame just yet), I can't get it fixed/replaced for free.

I have been attempting to load music onto my ipod mini with iTunes and am having the same type of problem. On a previous day, I tried for hours and got frustrated and quit. Tonight I have been reading about this type of problem on message boards and have tried twice to load the songs. The first time, it froze on song #79 when it had loaded 804.7 MB. The second time, it froze on song #42 when it had loaded 636.2 MB.
I don't understand why it had to reload the exact same songs and froze earlier the second time than it did the first time.
The previous night when I was attempting to load songs, it froze several times on the same album, but not the same song. SO, I took that album out, thinking that the songs might be corrupted.
Another thought that I had is that there could be an incompatibility between versions of software in the iPod and iTunes?????
PowerPC G3   Mac OS X (10.4.5)   iPod mini 1.4.1
PowerPC G3   Mac OS X (10.4.5)   ipod mini 1.4.1

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