IPod/iTunes 6 hangs during updating

I've just spent most of a weekend trying to figure out why a 40GB click-wheel iPod will not sync with iTunes. I'm at a bit of a loss here. I know there are several (long) posts on update issues - perhaps this is just another case. Here's the low-down:
Gear:
* iPod 40GB 'click-wheel' model, 3.1 firmware (2005-09-23 update), firewire interconnect direct to iMac (no dock)
* iMac G4 1GHz, OS X 10.3.9, iTunes 6.0.1, about 1600 songs
Symptom:
iPod appears on the desktop and can browse folders. iTunes starts. Hangs during iTunes update on a random song. Usually <20 into the list - but sometimes anything up to song 1000. Flashing 'do not disconnect' symbol freezes on iPod LCD, iMac hangs (Activity Monitor indicates a >90% cpu load on iTunes process, generally requires a 'hard' restart to recover the iMac - even after force-quitting the iTunes process).
Tried:
* Reset iPod
* Restore iPod with 3.1
* Restore iPod with 3.0.2 (2005-06-26)
* iPod into disk mode and restore
* iPod disk verify and erase using OS X Disk Utility, restore firmware
* New firewire cable
* iPod into diagnostics mode - run most tests including HDD scan (all pass)
* iMac disk permissions verify/fix
* Delete iTunes preferences and restart - library rebuilds
* Copy music to a new location, delete all iTunes data, now start afresh and
use add to library to rebuild library
* Removed songs and entire albums that sync freezes on (just freezes on
another song)
* Checked out iMac firewire ports with iSight
* Discussed with Apple Tech guy at Genius bar, agreed pretty much all steps
had been covered. iPod exchanged believing something like iPod connector
to be the issue. No difference.
So I'm pretty much convinced at this stage the issue lies with the iMac software. iPod and cable have been thoroughly investigated and changed out. iMac firewire ports work with iSight.
I've seen some posts suggesting deleting and restrong from the 10.3.9 update the iPod driver (iPodDriver.kext). This seems pretty drastic! I'm hesitant to go get a Tiger upgrade - this should work with 10.3.9.
Apologies for the long post - but I'd be interested to hear views at this point.
Thanks
40GB click-wheel Mac OS X (10.3.9) iTunes 6.0.1

Hey, you the man. I just want to say thank you. I hooked up a just repaired touch wheel iPod to my son's g4 iMAC, and it kept hanging on random songs and even the one's it transferred, it did slowly. I tried everything everyone else has, I did restores and erases forever. And it kept hanging up, so I had to frequently disconnect the iPod to get control back of the computer. This morning I was on the phone with Apple tech for over an hour. His conclusion was that because some of the songs weren't purchased from the Apple Store, I needed to manually transfer each song one at a time. I had to go, so didn't get to try it until later today and same problem. Again I called Apple tech support. Guy was very nice, on phone with him for 90 minutes, he didn't think the first advice made much sense. He gave up in frustration when we couldn't get into the disk utility because iPod kept going to automatic update. He told me to call back tomorrow and speak to a specialist. He said he's never had this much difficulty with an iPod. After the call, I managed to get into the disk utillity and do the erase and repair but didn't do anything. When I finally deactivated the auto update, manually transferring the songs one at a time didn't solve the problem. I read your post, started up after disconnecting the iSight firewire cable, took a chance of activating auto update of songs again, and voila, it transferred all the songs (all 176 of them) in about 10 seconds, like a warm knife through butter. And as they said on Saturday Night Live, it felt "like butter." I will call Apple tomorrow and tell them they really need to do something about this. In the meantime, I'll keep iSight disconnected whenever songs are being transferred into the iPod.
Again, your advice is much appreciated. Thank you for the post.
Steve
Mac OS X (10.4.3)
Mac OS 9.2.x

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Time period ends at 08-JUL-13 12.00.45 PM
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1 Row Lock Waits      155.44 | 99.88       1
2 Top SQL Statements 26.67 | 17.14        1
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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SQL statements were found waiting for row lock waits.
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please reply..
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