IPod Classic 160GB skipping songs after a few minutes play

I've got an annoying problem with my iPod Classic 160GB.  It gets to about 3 minutes or so into a song (sometimes more sometimes less then just skips to the next one.  It's about a couple of years old (I got it as a replacement when the battery of my 120GB Classic failed) and has been excellent.
It doesn't just do it when I'm walking along - I've put it on my desk now for experimental purposes and it's the same thing.  They all play fine in iTunes.
Most of my iTunes recordings are now Apple Lossless - the lower bitrate songs and podcasts seem to play through fine.  I've hard-reset and restored the machine.
I have heard some noises coming from the hard disc - could the HDD be failing?  Very disappointed if so - and what else can be done short of converting my large iTunes library to a lower bitrate?  But that defeats the object of having the Classic's high capacity which is the ability to store and play higher quality recordings. It never did this in the past - nor on my original 120GB

I've done the iPod diagnostic tests on the HDD (select-menu then select-back) and it comes up with no errors or bad sectors.  Hmm

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