Dead iPod touch during 3.0 update process

Cross-posted to "iPod Touch" forum... But because another person had a similar problem with Vista as well, am posting here too in case someone can help...
...Not only during update to 3.0, but also during update to 2.2.1 and during a restore attempt 6 weeks ago. All 3 "dead" iPods have been replaced by Apple - I'd like a solution...
I have videoed the update taking place and the iPod dying during it - sadly it is in MOV format (439MB) and I cannot convert to an uploadable version for Youtube... By DEAD, I mean, no power and will not display ANYTHING on the screen. Simply won't power up again.
This is what happens: Download update using iTunes... Extracting software... Backing up iPod... Preparing the iPod for the software update... (iPod shows USB plug and CD - then apple logo...) then the updating progress line appears on iTunes and on touch. Updating iPod software... Verifying updated iPod software... Updating the iPod firmware... White progress line on iPod disappears after a few seconds and screen goes black. Error message displays on iTunes - "The iPod xxxx could not be updated. An unknown error occurred (6)"
iPod is now dead and needs to be replaced,
1) Has anyone experienced this?
2) Has anyone SOLVED it?
Maybe related is a problem with some videos that have happened recently (and were the cause of me trying to restore the iPod last time it died) MP4 (or MPV files) play for about 20-30 minutes, then screen goes white, then black, then apple logo appears, then iPod returns to home screen after about 30 seconds. My usual solution to this has been to remove all videos, photos (which are corrupted by this time), audio, and then re-sync back.
I'd appreciate ANY help please. I intend buying an iPhone soon and would like to know that the problem won't occur on that, every time I try to restore.
Cheers!
Martin

Answered in another forum. Probably the Zonealarm firewall...

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