4th gen i-pod locks up

Almost a year ago the hard drive on my 4th gen I-pod failed complete with terrible clicking and grinding sounds (not surprising as I leave it in the car all the time, hot and cold). After $60 and 10 min I installed a new drive and all was well for several months. All of a sudden it started skipping to the next song by itself. This wasn’t so bad but then it started locking up, for 5 min, until the battery went dead or somewhere in-between. The display would lock up too and if the light happened to be on, that would stay on as well. I tried “restore to factory settings” several times from I-tunes and it would work for a while, an hour or a few days but then the symptoms would come back. It would also occasionally work after letting it unlock by itself. Unfortunately this happened on a solo road trip from NY to southern SC. I mostly use the unit connected to a USA-Spec factory car-radio adaptor but to rule that out as the problem, I used it stand-alone and the problems persist, and my wife’s nano works fine with the car adaptor.
Any ideas on a solution would be appreciated, thanks

Try connecting it to your computer, and with iTunes NOT running, reformat it using Windows. You can do so through a My Computer or Windows Explorer window. Use a full format instead of any options for a quick format.
If that process completes, run iTunes and immediately run another Restore to install and initialize the iPod's software.

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