IPod not syncing / scrambled by iTunes

For the second time this month, iTunes 10 has decided to freeze/crash while working on my iPod. The first time I was left with an iPod that seemed to still have everything on there, but it was all unaccessible. It claimed there were 0 files on there, but the memory was almost full so clearly the files were still there.
I had to format it and start over. Wasn't very happy considering it was a 160gb iPod that was about 158gb full, and much of the last month has been spent trying to get it back up to where it was before. The stuff that I hadn't completely lost forever, anyway...
Now, yesterday, iTunes has pulled the same trick again, but the results have been slightly different. The iPod is basically okay - all the video/audio/photo files are still on there (minus the cover art, apparently) and are all still accessible, but it won't sync properly anymore so I can't add anything else. And whenever I plug it into the computer it just sits there with the 'connecting' arrows spiralling round and round. iTunes just freezes. Windows goes from detecting my iPod (name and all), to just detecting a 'portable audio player' that doesn't have a disk, and it won't let me format it in either normal or disk mode.
What I want to do is just wipe the iPod and start over again, since this time I've kept a backup of all my ripped music and audiobooks so I should just be able to reload everything in a fraction of the time. I've removed iTunes 10 now since it's done this to me twice and I'm back on 9 but I can't get to the 'restore to factory settings' button because iTunes just doesn't want to know. Any ideas?

Antivirus has a tendency to freeze Itunes sync Operation with Ipod Classic, causing a timeout, which corrupt your Ipod filesystem, so when iTunes cant read the iPod, it is pointing to this problem. Other causes is when your iPod hardisk is dying, or your battery is dying causing hardisk crashes.
My suggestion.
Connect your Ipod to the PC and run chkdsk, to fix any iPod diskerror, then disconnect it, after chkdsk complete.
Disconnect your PC from Internet. (just to make sure no nasties creep into your system while you syncing.
Stop the Antivirus program
Connect your Ipod to the PC
When Itunes Open up, Restore your iPod please, this is for iTunes to map correctly, to fix the corrupted filesystem.
When Restore complete, eject the iPod and reconnect again.
Sync your ipod, preferably manually Manage in small batches and disconnect after every batch, to check that all is well, since you got such a huge library.
When all sync is complete, and iPod disconnected, start back your Antivirus and connect back the Internet.
Good Luck! and have a Nice Day!

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