IPod mysteriously dying during sync

About a month ago, I received a 3rd gen refurbished iPod Touch 32gb as a replacement for my original faulty product. However, whenever I try to sync it to my computer, the iPod makes it about half-way through the sync process before suddenly shutting off and showing the Apple logo. No error report is given on iTunes. At this point, it begins a cycle of shutting off and then attempting to reboot every 10 seconds or so. Most of the time it will not let me put my iPod into recovery mode. Sometimes, my iPod will mysteriously recover for no apparent reason and then return to normal functionality, albeit without any songs or videos loaded onto the hard drive. Usually, however, I must leave my iPod unplugged and let the battery drain before it will be recognized in iTunes once again. However, usually the exact same cycle occurs when I attempt to resync. The problem never seems to be perfectly consistent--on some occasions I have encountered an error message when attempting to sync.
I am running iOS 4.2, OS X 10.6.5, and iTunes 10.1, and my original device had no problem syncing with iTunes. I have run through all of the troubleshooting options offered on Apple.com, scavenged trough many forums but still have not found any solutions to this problem. I even sent it in to Apple, but they said that there was no problem with the device. I guess it would make sense why they did not find an issue since it usually restores just fine. And now, of course, they want to charge me for a phone call. I am extremely frustrated since I have not had a fully operational product ever since I ordered my original device in July! Sorry, had to rant just a little bit...
Somebody please help!

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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