Ipod (2nd gen) Does damage occurs playing through car stero?

I have tried playing ipod shuffle (2nd gen) through
car stereo with aux cable. Plays fine for a while
then 'blows out'. ipod will then not take a charge
and gets very hot. Had ipod replaced twice already.
No problems playing first gen through car stereo.
Don't want to risk playing with my second
replacement. Any suggestions?
As Scott has already noted, AVOID using a connecting cable with plugs that have metal plates at the end of the plug shaft, they may cause shorting to the Shuffle's aluminum case. The same issue of potential shorting does't exist with the 1st Gen Shuffle...
Simple short term solution is to cut a round isolator disc out of thin plastic and insert it on the plug shaft...

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Thanks for providing a good amount of detail.
Enable disk use is a setting (checkbox) on the shuffle's Settings tab in iTunes. It allows you to see the iPod's "disk" on the Desktop continously while it is connected, so that you can copy files to it using Finder (like it was a USB flash drive). The light blinks as a warning to eject before disconnecting, because the iPod's disk is mounted. If that checkbox is NOT checked, iTunes only mounts the iPod's disk when syncing, so the light does not blink most of the time (and you can disconnect it without ejecting).
Although you have confirmed that the USB port on the external drive (Is it an OWC miniStack?), which is the same as a powered USB hub, works with another iPod, you may want to disconnect something from a direct USB port temporarily. Connect the shuffles docking cable there, to confirm it's not the port causing the problem.
If you connect it and run Disk Utility instead of iTunes, does it appear in the Disk Utility sidebar?
Since this is a 2nd gen shuffle, and you use a Mac, you can try using the iPod Reset Utility
http://support.apple.com/kb/ht1238

Ipod (2nd gen) Does damage occurs playing through car stero?

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