Ipod keeps disconnecting during sync

Just adding my issues to the pile. Same as many other, I consistently have my 80GB Classic ipod disconnect with the "wrong volume in disk" message. It will make it through about 2100 of the songs before it stalls out and disconnects.
Every time it happens, the ipod gets stuck in sync mode, even after ejecting the ipod in itunes, and I have to disconnect it. When the ipod comes back up, there are usually 0 to 7 songs on it, and when I connect it to itunes, it shows 15GB of "Other" data, which is what should have been the songs.
I have tried the fix apple posted for the -50 error, didn't work.
I've tried syncing automatically
I've tried syncing manually (both in one large batch, and in many multiple smaller batches).
I've tried turning off album art prior to syncing.
I've tried syncing across USB 1.1 and 2.0, both with older ipod cables, the new cable that came with the classic, and a 3rd party cable.
I've tried IDing the specific songs that are loading when the ipod hangs and disconnects, thinking they might be corrupt, and then deleting them, and after restoring the ipod and syncing again, it will hang again, this time with a song that loaded just fine the previous time, so there appears to be no rhyme or reason to it as far as the song files are concerned.
I'm about to try uninstalling and reinstalling itunes, but I doubt it will help.
How did things get so bad from the 5.5 to the classic? This is crazy.

Just an update:
I took the iPod to work where I have a much smaller library, about 5 GB (my iPod is an 80 GB model). I reset it and synced to the work computer and it worked. It seems that it can only handle a smaller database? I also ran some diagnostic tests ala
http://www.methodshop.com/gadgets/ipodsupport/diagnosticmode/index.shtml
It won't pass the FW / USB detect test. Perhaps the unit is faulty. In any case, my next step is to try to return it for exchange at Best Buy, though it is 5 days over the 30 day period. How convenient! Nothing about this exprience has been convenient. They should call this thing the iClod.

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HiImTye wrote:
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First off thanks to all the views and no replies, lots of help....... :sarcasm ended::
anyways, I went to the apple store and they told me the hard drive in the iPod was damaged. If you drop it one too many times, work out with it etc, it takes a tole on the iPod. The hard drive couldnt write the files being transferred through the sync.
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Ipod keeps disconnecting during sync

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