160 GB IPod will not sync my entire library

Question

I own a 160 GB IPod Classic and it's been acting fine up until a few weeks ago. My total music/video library is 6621 songs, 32 music videos, 2 TV Shows, 14 movies which brings it as overall total of 6669 items in my library. I attempted to sync my IPod with newer songs that I recently purchased from Itunes and it would not sync, it actually told me that it did not recognize my IPod.
So, I ejected my IPod and reset the IPod. The music on it was totally erased and my IPod was empty. I then restarted my computer. I plugged it back up using a different USB port to resync. Once it got up to 4,170 or 30 GB of my library, it froze. I had to manually eject it. I did the Restore option on my IPod putting newer version software on it and it's still acting buggy.
My husband has an 80 GB IPod Classic and his syncs my entire library just fine without any problem. I can no longer listen to my IPod because it will not sync to my current library. It's no longer under product warranty because I purchased it back in 2009 so I just need to know if this can be resolved w/o me having to have it repaired at a high cost.
Please HELP ME
Aysha

Answer 1

The most likely problem is a damaged source file, but you could try this technique for populating the iPod in stages.
*Break up large transfers*
In iTunes select the menu item *File... New Smart Playlist*. Change the first drop-down box to Playlist, the next to is and the next to Music. Tick against *Limit to*, type in say 10, then change the drop-down to GB, and set the last drop-down to artist. When you click OK you can enter a name for the playlist, e.g. Transfer. Now sync this playlist to your iPod rather than your entire library. When the sync is complete modify the rule ( *File... Edit playlist* ) to increase the size by your chosen amount, then sync and repeat. You can experiment with different size increments, if it doesn't work just choose something a bit smaller until it works each time. Before long you should have all your music on your iPod. Once that's done you can move on to other media such as podcasts, videos, photos, playlists etc.
tt2