IPod problem - does this sound like a hardware or software issue?

My iPod (80/video) sometimes plays but without sound. In other words, the time counter progresses, but there is no volume. It is very intermittent, but annoying nonetheless, because I need to restart the ipod to get sound again.
I've had it back to Apple twice, and they were not able to reproduce the problem.
Now, after spending a lot more time playing with it, I know how to reproduce the problem.
This is when it happens:
1. Pause iPod
2. Remove headphones
3. Let ipod turn off by itself
4. Reinsert headphones / play ipod
When I turn it back on again, there is no sound from the headphones and I need to restart it.
So, the normal scenario is that I get to work, pause my ipod, remove the headphones and plug them into my laptop, letting the ipod turn off by itself after a few mintues. When I go to leave again and plug my headphones back in.... no sound.
It happens with any music file or video file.
Now, if this is a software/firmware problem, then I will patiently work around it. But if it might be a hardware issue, then I will send it back again, especially now that I know how to reproduce the problem reliably.
Of course, I've restored the iPod many times and have tried it on different computers with many audio and video files. The problem persists.
Any thoughts?
Thanks.
sam
5G 80gb Mac OS X (10.4.9)

I have the same problem (sort of). I used to think I was losing the sound output, until I notice that the iPod errouneously and randomly turned the volume down to zero. Since this occurs while I'm driving with the cassette adapter and plug-in power adapter in use, nothing is touching the face of the iPod.
Now for the bad part. It is now starting to go the other way. I'll be happily listening to the iPod when it suddenly pegs to 100% volume. Sometimes it jumps around - up, down and then to zero.
I sent my 5th gen 60 gig iPod in for servicing. I got it back yesterday with no repairs and it has already started pegging at 100%. If this isn't a problem with the iPod (according to Apple) then there is a MAJOR software bug that needs to be addressed. I don't like getting "shined on" by Apple just because they didn't reproduce the problem during their half hour of troubleshooting.
MacPro, MacBook Pro, Mac Mini (Intel), iMac (Intel) Mac OS X (10.4.9)

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