All new iPods broken (?)

hey everybody,
my old, 3rd gen iPod broke a while ago, so I got a new 60GB 5th gen to fill the gaping hole in my heart ... :P
anyway, i got it engraved, so it came straight from the factory in China, complete with the latest software etc. first of all, it was USB, which i think is stupid, because i don't have USB 2, but w/e. then, i found out it was pre-formatted in FAT32 (WINDOWZ eww). after reformatting it with the ipod update, i attempted to load my music onto it. however, iTunes kept on spitting this error message out, "cannot read or write to disk" every 100 songs or so.
i returned it, and got another one.
this time, it was the right format, but it had the same problem.
i returned it and got another one.
same problem.
i returned it and got another one.
THE SAME PROBLEM!!! AAARGHHHH! needless to say I am pretty p**d off at apple right now ...
well, I looked at this article, and narrowed the possible problems to these things:
1. broken HD in iPod
2. bad cable
3. bad USB chip
I don't have a PCI slot on my PowerBook and I don't know if i can swap the chip, the cable looks fine, and I hope that apple hasn't lowered its standards to the point that i got 4 bad hard drives in a row.
I am trying to load 9,000 songs to my iPod in a single session, could that be a problem?
sorry, this is a monstrosity of a post, but I need this fixed by the end of the week, i am leaving to europe for the summer.
cheers,
-lpod
1.33 GHz PowerBook G4 12"   Mac OS X (10.4.4)   1.25GB DDR SDRAM

Since your powerbook doesn't have USB 2.0, and never will, you are stuck using USB 1.1 for syncing.
While USB 1.1 has a theoretical maximum transfer speed of 12Mb per second, you will really only get about half that.
I'm ballparking the size of your library to be about 30-35GB, maybe larger.
It would take hours to transfer that entire library at once.
What may be happening is your powerbook is going into sleep mode, or standby mode during the transfer which is causing the USB sync to get interrupted.
I don't think the problem is the USB ports, cables or the iPods themselves. I think this is simply the result of trying to transfer too much data at once over a very slow link.

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