ITunes library won't copy to 2nd iPod within household -randomly selects

Hi, we have invested in a 2nd iPod. I have a 160gb classic and my husband now has a 80gb classic. I'm trying to copy all of the iTunes library over to his new iPod but out of 6k songs its randomly selecting 1013. We thought it was the new iPod so took it back to the shop but the replacement version is taking exactly the same details as before.
As far as I can see there is MORE than enough space to take the files so don't think this is the problem.
Now I have to admit that I am a bit of a techno idiot so would appreciate any/all replies to be step by step and idiot proof.
Thanks in advance

Hello,
First, check the iPod's preferences in iTunes... click on the iPod under Devices in the left-hand column. This should display the 'Summary' page (you'll see a picture of the iPod). Click on the Music tab, and make sure it is set to Sync all songs and playlists.
If the preferences are not set that way, change them so that they are, and then click Apply in the lower right-hand column. If they are already set that way, you might want to consider restoring your iPod in iTunes. This article will go over that in detail:
http://docs.info.apple.com/article.html?artnum=60983
If the restore doesn't help, try changing the iPod drive letter, per this article:
http://docs.info.apple.com/article.html?artnum=93499
Hope this is helpful
CG

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