IPod freezes around 1.28 gigs of music

I've been a this awhile trying various ways to a solution but all come down to this. I can only manage to get about 1.28 gigs of music on my iPod. I did a manual "dumping" of songs onto my ipod from iTunes so I could at least control which songs I wanted on there. Anyway does this mean that there is something wrong with my iPod?
3rd Gen 15gig scroll wheel iPod (with four buttons under the screen)
iPod software v2.3 and iTunes 5
thanks for any help and advise

Could be that it's writing information to a bad sector of the iPods HD.
Run Techtool Pro v4.0.5 on the iPod and scan the disk surface, this should verify if any bad sectors are present or not and if found it should make sure information is not written to those sector(s) anymore.

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    Hello, VvioletT. 
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    iOS: Troubleshooting USB-related alerts when syncing
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    When I bought my Mac the guys at the Apple store were shocked that I was having this problem and practically begged me to bring it in so they could see what it wrong with it. I will post an update when i do that.

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