IPod Classic 160GB Reboot loop BUT Disk Mode Works!

I have searched the internets and have yet to find someone with the same problem as me.
I have an iPod Classic 160GB which is stuck in a reboot loop (apple logo appears for 10 seconds, then restarts again). This happened shortly after using it as a disk to transfer a file from a Linux machine to a PC. This is probably not the culprit though as I have done this many times.
The reboot loop continues and neither windows nor a mac will recognize the iPod until I put it into disk mode. When I do this, it functions perfectly. I can move files to/from the disk, add songs in iTunes and then play them from the iPod. I am able to restore the iPod but when it tries to complete the process it goes into the reboot loop.
So, in brief, I have tried:
1) Resetting the iPod (duh).
2) Restoring it using iTunes while in disk mode on a Mac and a PC.
3) same as above but manually choosing an older firmware version.
4) Manually formatting the drive using a Mac and a PC.
So perhaps there is something wrong with the iPod that is not hard drive-related or there is something wrong with the firmware partition. Needless to say, I'm baffled.
Answers such as "Send it back to Apple." or "You're screwed, it's a brick." will not be considered helpful unless they accompanied by an explanation.
Thanks in advance.

Some more info:
I can get into diagnostic mode by pressing select and REV, but I can't force a disk scan by pressing MENU, SELECT, REV, and FFW.
Any help?

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I have an iPod Classic 160GB in version 2.0.4 that is not recognized by itunes.
It's about 2 years old and had presented a few problems with sincying in the past, but I hadn't tried to sync it for a while.
I've transfered all the music from my Windows PC to my Mac, and the iPod was Windows formated.
It started presenting a problem to transfer all my music content from iTunes (Mac) to the iPod, but after severel hours, it only transfered a few hundreded. I've tried it several times.
So, I tried to restore it, both in Windows and Mac PCs, but the problem persisted. A hard reset didn't solve it either.
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It is recognized in the desktop tough.
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1. Hard Reset.
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3. Use Disk Utility. The disk verification says everything is in order. I've erased all content as well as format it in Mas OS Extended (Journaled). Later I've tried to erase it again but now displays a message error saying it cannot unmount the disk.
4. Used differente USB ports.
5. Saw all Apple support solutions. None worked.
6. Researched a whole bunch of forums, including this one. Noticed a lot of people with the same problem, but had difficulty finding one more recent, so I decided to open a new discussion.
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Itunes (10.6)
Mac OS Snow Leopard.
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It seems to be working now. Amazing!
I would like to thank you both for the help, CaliforniaHighwaysGuy and AncientMumu.
Here's what I did. I wasn't getting folder acces from my Windows XP because it was Macintosh formated.
So I connected it again to the Mac and used an online tutorial to be able to access the hidden files through Terminal. (I'm not sure if it's allowed to post links to tutorials from other sites, but I'll look into the rules and post, if possible).
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Already reconnected the iPod and it was once again recognized after a few seconds.
I really appreciate all the help.
I'll try to updated this post in a few days saying if it's still working properly.

IPod Classic 160GB Reboot loop BUT Disk Mode Works!

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