Classic-160 Continues To Crash

My iPod Classic-160 is the third one in my possession; the other two have been brought back to Apple and replaced-cheerfully. All have misbehaved in the same, exact way; they crash when a command is implemented in conjunction with a large playlist (in the 20,000 to 33,000 song range).
In some instances the iPod will crash (or freeze) immediately when selecting the first (or any) song to play in a large list. Many times the iPod will play the music yet if I push the menu button, it crashes.
The following are the troubleshooting steps I have taken:
1: Restore-many times. 2: Resets-countless times. 3: Firmware update (somewhat improved the performance; prior to the update the iPod would crash if I even looked at it! 4:Trashed-iTunes then downloaded and installed fresh copy. 5: Trashed iTunes library files (Data and .xml) and started over with a fresh App & library. 6: Ran every media file through the Tech Tool Pro gauntlet and it found nothing corrupted. 7: Resynced my old 5G iPod Video, filling it up with 70 GBs of assorted media files. It plays as flawlessly as ever.
Please chime in if you know any trouble-shooting steps that I may have missed and that could help.

Identical symptoms, no solution to offer though! Surely this is the sort of thing that constitutes a stress-test, without which the "160Gb iPod" isn't signed-off and is therefore a misnomer.
Thanks for telling me the restore didn't work though- after having many problems syncing, I've found I have to do it piecemeal over three days, and if it's not going to solve the problem, I'll not waste my time (everything else works).... I'll just wait for the software to get up to speed with the unit!

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Classic-160 Continues To Crash

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