Ipod classic 160gb - multiple deaths! Why?

In the last 6 weeks 3 ipod classic 160 silver machines have gone belly up.
Why is this happening? Apple refuse to say.
I am very (very!) IT savvy yet nothing appears anywhere as to why. someone must know.
one died on first sync. that was replaced. (it was a US model too, but was replaced with a Euro model - I was well cheesed off). This one has now died. 5 weeks later.
another, which was itself a replacement for one that died last May 2011 has died after 8months (out of guarantee - typical!), just as I tried to run a genius list.
All possible solutions attempted on all models, independently and with telephone support. Nothing doing!
What on Earth is going on?
I don't misuse them, I don't jolt them, they are kept in heavy duty protective cases! I just don't know.
One telephone operative did let slip that my itunes library is very big and 'probably' (his words) caused at least one of the failures (the first, when it failed on first sync)
I must be a masochist, because I keep coming back for more failure. It has got to the point now when i expect it to happen every time I use the infernal machines.
Does anyone have any knowledge / thoughts / input on this?
Any support / sympathetic words would be welcome.

Hello there,
Whoever you are, you are a saviour.
I followed your instructions to the letter and it all went (mostly) smoothly.
Following the reformat, itunes recognised and restored my ipod, then synced.
The first time, the end result was a freeze and return to apple logo.
I tried again, with a couple of changes.
1) i synced the library (large at 134GB) in stages
2) i'd noticed that 'enable disk use' had been checked on the manage ipod window in itunes, so unticked that. This may not be relevant. I've subsequently noticed that this has been ticked on all my families ipods, causing the sync / charge process to run slowly (i think) - especially the disconnect at the end. I'm sure I've never ticked this box. Maybe it's not connected.
Anyway, the older, out of waranty ipod is working again. The other, in waranty one I've returned for a service and probable replacement. Thought I might as well. Will take care syncing though, and will know what to do if it freezes in future.
It does beg the question though - why did the apple telephone operatives not talk me through this procedure - it would probably mean that I would still have my north american ipod rather that the inferior euro model it got replaced with.
Thank you very much.
asters2

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First of all, let's get a few things straight.
me too said:
I purposely created several different threads because I wasn't sure which discussion to enter in and it is my opinion that it fit into any of these categories.
Actually, you posted the same thing into the iPod Classic forum four times, and one additional thread in (if I recall correctly) the iTunes for Windows forum. That's impolite; at best it simply clutters up the forum with unnecessary threads, which can cause other people's valid posts to be missed in the mass; and at worst, you'll get responses to more than one of your threads which will confuse, not just you, but anyone trying to help you. I've seen it happen.
I'll ask again, please refrain from multiple posting.
me too said:
I am also aware that the "other" is my album art.
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There is always a small amount of Other on an iPod, but large amounts of Other indicates data that has become corrupted and cannot be used by the iPod.
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Ipod classic 160gb - multiple deaths! Why?

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