Getting a "driver error" message when syncing

The trouble started when my iPod keep getting hung up on a few songs, or would only play half a song, or skip over a bunch of songs. They guy at the apple store said I should wipe it and install the latest iPod software - which is did.
At the same time I moved my iTunes and entire library from my hard drive at work to an external hard drive. Once I successfully moved iTunes and my music I tried syncing my iPod to iTunes and it uploaded about 400 songs and then I would got a message "the drive is not ready for use; it's door may be open. please check drive f: and make sure that a disk is inserted and that the drive door is closed" I took my iPod to the apple store and they tried it on their PC there and it worked just fine. I mentioned that I my computer was a USB1 and the apple guy said that might be the problem - so I installed a USB 2 drive on my computer, but still go the same error.
I have tried uninstalling iTunes and reinstalling (the suggestiong of the guy at the apple store on my second trip there) I have tried to install both my iPod and iTunes on 2 different computers (and different windows operating systems - 2000 and XP) and still get the same problem. I don't think it is the external hard drive because a colleague at work is using the same set up successfully. But just in case it was I move everything back to my hard drive and tried it again, with the same problems.
Initially I could load about 200 songs as a time before I got and error, now I can't even load 20. I have tried only putting a couple hundred of songs on my iTunes at one time and then syncing, but still the same problem.
Sorry for the long question, but I just don't know what to do next.

This is an add on to my original question.
I was prompted by iTunes to restore my iPod which I did. It seem to be working OK until I got this error message.
"Attempting to copy to the disc failed. The disk could not be read from or written to".
Any ideas?

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