IPod stops syncing after a while, won't eject and then crashes iTunes

Whenever I try to update my iPod Classic 80GB, after 1000 songs or so the iPod stops syncing (gets stuck on a song). Then the iPod won't eject, even when dragged into trash.
Then, when trying to eject iPod or quit iTunes, iTunes crashes and has to be force quitted with iPod cable removed.
When I check my iPod it says there is no music/photos etc on it.
I have reinstalled the latest iTunes and restored my iPod with the latest version, my OS software is all up to date too.

Actually at 1200ish songs the iPod hard drive starts making some severe clicking/clanking noises. I'm guessing it means the hard drive is screwed since it's the same symptoms as my last iPod
Why does this happen? Both my iPods were about 2 years old when the hdd's started clicking, surely hdd's last for more than two years?

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