If you can solve this problem, then you are a true iPod Classic Genius !

So I have talked to every level at Apple's iPod support, and to list all the things they made me do would exceed the size limit of this message board. They even made me send back my original iPod Classic, and I had to wait for almost 1 month to receive my replacement. Here is a summary of my problem, that they (Apple support) have not been able to solve :
- I have a very extensive iTunes collection - over 77,000 songs. All of them were ripped, using iTunes.
- I use the ID tags extensively - i.e. every field is used, and the comments are filled to the maximum allowed characters.
- I am not able, to synch more than ~ 23,300 songs to any of my two 160 Gb iPod classics - therefore, including my exchanged iPod, this issue shows up on three different iPods.
When synching more than 23,300 songs, my iPods are no longer able to play any songs. In the 'About' menu, the iPod shows the wrong number of songs (i.e. 17,300 instead of 24,000) and a huge amount of 'disk space used' is flagged as 'other' (in orange). When clicking on 'Album' or 'Songs', the iPod shows the message 'No songs found'.
When synching less than 23,300, I am able to resolve this issue by restarting the iPods after synching. However, even when synching less than 23,300 titles, the iPods show the wrong number of songs, right after synching, and the huge amount of 'disk space used' for 'other'. Therefore, I have to restart my iPods every time I synch them.
The same problem occurs when using my old Power Book G4 (OS X 10.4.10), and on my new 2.4 GHz MacBook Pro (OS X 10.5.1).
I am using an external HD to hold my music files, which is directly connected to my USB2 port on either Laptop.
I have uninstalled and re-installed iTunes and all the firmware and software is up-to-date.
I have rebuilt my iTunes Library from scratch several times.
I have no problem, playing any of the 77,000+ songs in iTunes.
My assumption is, that there is a size limit for the iTunes library index file on the iPod. Can somebody confirm this theory ?
It seems funny, that the same problem shows up on three different iPods using two different Mac computers.
Does anybody have the same problem ?
Is this an issue that Apple is ignoring ?
Does anybody know, how this can be resolved ?
Thank you very much for your help.!
Message was edited by: Rochelle Renee Christen

Hi There,
I have the exact same problem as you. I'm on my third ipod 160gb. All three have had the freezing and resetting problem. Like you my problems only start once I try to sync more than about 20,000 songs, which is around 90gb.
I have a 140gb music library. If I sync 70gb of my library it works fine. If I wipe that and sync the other 70gb it works fine so I know my mp3 files are okay. If I try to upload the whole library it freezes when I try to select any music.
If I'd only wanted to sync half my music library I'd have bought an 80gb ipod.
I thought firmware 1.1 and itunes 7.6 would solve my problem. No. Exact same problem. I contacted apple support. A genuinely helpful guy advised me to rebuild my music library and change my ipod drive letter. With baited breath I did all this, then restored my ipod to start from a clean slate. I synced my library in 10gb chunks... and it froze up around 90gb just like it always does.
What upsets me is the hours I've spent glued to my PC re-syncing music, searching through forums for answers. I'm absolutley pig sick of it. I never had a minutes trouble with any of my other ipods.
Please, please, please apple investigate this problem, it only happens when these ipods are over half full. Please let us have a firmware update that addresses the bugs us folks are complaining about instead of adding new features we'd be grateful for if only our ipods worked in the first place.

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