Ipod Nano - Not enough room

Have gone through every forum I can find and have found no solutions. I had my 16gb iPod Nano stolen. Bought a new one (refurbished). Trying to sync with itunes with the exact same playlist and it says there is not enough room. Have restored 4 times to no avail.
Converting songs to 128kbps
Have unchecked all videos and podcasts
Only have one playlist selected.
Status bar at the bottom says I have plenty of room but as soon as I hit "sync" the status bar jumps to completely full and get error message that it cannot sync because there isn't enough room. I have deleted about 100 songs and still get same problem. As I said I had the exact same iPod before and had used the exact same playlist on older 16gb model with no problem whatsoever. Fit all songs with room to spare.
Any ideas? Am thinking I got a lemon.

This is the image I get before hitting sync. Then it immediately jumps to completely full.

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x

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