IPod from 2006 just started melting while charging HELP

My sister and I both got iPods around the same time in 2006-2007, about 6 months apart. Neither of us had a warranty on ours after these incidents. She started to notice damage to her iPod about a year and a half after having it, took it to a Genius Bar in Minneapolis - said that charging it melted through the click wheel. They replaced it, no checking, no questions asked regardless of having no warranty. Mine (same model) also was having issues. Before it melted, I noticed it kept telling me there was an error and that it was corrupt. I restored it dozens of times to say the least, and waited in Indianapolis out of state for +40 minutes before they checked it, told me TO RESTORE IT, and couldn't do anything about it because they plugged it in and said it was probably an internal error.
Then 6 months later it started to burn while I charged it (while still being corrupted every other time I'd plug it in to iTunes) and there is now a crack that was not there before, on the screen. So everything is messed up, there is not an Apple store less than 4 hours away and I do not have the money to send it in to tell me it needs replacing.
Is there any way they would deny me to have it replaced unlike they did for my sister? I haven't been able to bring it in since then because of location and it is SO FRUSTRATING, because it is 3 years old, yes. But the fact that my sister had no warranty and they didn't even have to plug it in and replaced it, while mine says it has an infinite-long corruption and no one does squat.... Will telling them my sister's was replaced with a new one free off her warranty do anything? Because I am afraid they won't even replace it after 3 years and all of a sudden charging it just burns straight through the plastic... Anyone help?!

Try another Cable.
Are you charging from the mains..?

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