Itunes and ipod freeze during sync

hello,
firstly, i would like to thank all you kind souls who post to this forum with very helpful suggestions. you have helped me with many past difficulties.
my present issue concerns transferring songs from itunes to my ipod (4th generation). here's the story:
on friday, my ipod started acting funny (skipping songs, etc.). by saturday, it would no longer do anything (folder with !, resetting did not help). this had happened to me before so i did not freak out and figured i just had to restore (that had worked the first time around). however, when i plugged in my ipod to my computer (powerbook g4, just three weeks old), it was not recognised and i was prompted to initialize the disk. i then came to this forum and read pretty much everything related to this kind of problem. countless resets, erases, partitions, etc., later, i was able to get the ipod software back on the ipod. it seemed all normal but there was no music on it (makes sense since i'd restored it). but then...when i plugged in my ipod to sync it with itunes, it would freeze at a given song (not always the same one, sometimes 31 songs into it, sometimes 500). i came back to this forum and read that i should reset my ports, which i did. didn't help, the sync still freezes both the ipod and itunes.
so that's where i'm at: i have the ipod software on the ipod, but i can't sync it with itunes (i.e. i can't get my music onto it). my brother thinks i have bad blocks (or sectors). is this a possibility? the ipod does make some noise (not sure whether it's the infamous clicking...).
so here are my questions:
1) is there anything i haven't done yet that could get the ipod to sync with itunes?
assuming i have done everything and the problem is with my ipod's hard disk:
2) would a program like disk warrior potentially be able to fix the ipod?
3) would it cost me less to have the ipod serviced than to buy disk warrior?
4) is there somekind of open-source or freeware disk repair utility that could perhaps repair my ipod's disk?
thanks for reading and i really look forward to any suggestions.
gen
p.s. the ipod's more than a year old, so no longer under warranty.

Okay, I got it to work tonight...
My U2 iPod would freeze while syncing. I restored and tried to sync and it would freeze on different song #'s. All the while I heard a clicking sound coming from the drive that I never noticed before. It would just click once in a while, not repeatedly.
My fix: (a version of the carpet drop) While the iPod was on and spinning, I held it tight with my right hand, facing me and smacked it's side into the palm of my left hand, simulating the amount of force that it would incurr from a waist-high drop onto carpet.
Now, this force was sheer approximation, being that it would be too time consuming and difficult to calculate this exact amount of force. I mean, my waist may be higher/lower than the original carpet-dropper, and not to mention the plushness of the carpet! Who knows if he did it on Shenandoah Shagg or maybe just some Bermuda Burr Rug?!
By the way, the problem started after being left out in the car on recent cold nights... hmmmm, my iPod thinks me a jerk.
Anyways, here are some previous attempts at fixing my situation (in no particular order):
1) restored from 5 different iPod updates (2004-11-15, 2005-02-22, 2005-06-26, 2005-09-23, 2005-11-17)
2) tried to fix with Disk Utility
3) tried to fix with Tech Tool Pro
4) tried to fix with Disk Warrior
5) tried to initialize multiple time (even writing zeroes)
6) manual sync
PB-15"Al; G4-DP500   Mac OS X (10.4.3)  

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