5G iPod no audio after full charge

I have a new 5th gen ipod and having problems with the audio playing after charging the unit.
I leave the ipod connected to the USB cable overnight, but when I go to use it later in the day, trying to play songs or podcasts, there is no audio! This has happened about every time I've charged it. All menu navigation and selection of things to play works fine, but there is no audio to be heard. Song, podcasts, videos, no audio for any of them. The timer ticks as it plays, the status bar shows it proceeding thru the play, but no audio.
I don't know yet if it's related to charging but it seems to occur after a charge. I have to soft-reset to get it to work again. Then it works fine until the next time I charge it. This is getting really annoying. I have updated the software on the ipod to the latest available. I have the latest iTunes.
One day after soft-reseting and then playing audio ok, I went to use it a few hours later (no charge inbetween) and it wouldn't play audio again. This time I also had a terrible time trying to soft-reset it, it wouldn't! I pressed the center select and top menu positions on the thumbwheel and it wouldn't go, try after try! After about 5 minutes of trying it finally did.
I have an iSkin eVo case on my ipod. I don't know if this would affect it but I also left the single sheet sticky plastic on the face of the ipod that came from Apple. Once the audio starts working, it works fine. No problems selecting, navigating, changing volume, moving the play-head forwards, back, etc.
Anyone else have this issue? I'm about to take it in for repair/exchange.
G4 Dual-533 Mac OS X (10.4.5) ipod 5th generation (video)

Well, I spoke too soon... two days of using the ipod and it worked fine, BUT I realized I didn't leave it charging over night. Third night I had it on all night so a full charge and once again it didn't play audio in the morning. I shows that it's playing, the time for the song/podcast changes, the play symbol is on (not pause) but no audio. I have to reset the ipod and then it works fine. Then later in the day I try to play it and it won't even play! Menu navigation works but I click on the play button and it won't change the play time.
So I'm back to square one! This ipod has a problem!
Any ideas? I'm ready to take it in to the Apple store before the warrantee runs out.

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