Itunes won't sync to my brand new ipod classic.  It says "The Ipod cannot be synced because it cannot be found.

I have been onto Apple by phone, and into the Apple store where both of them recomended that it gets replaced.  I did, got a brand new ipod classic, and i still have the same problem.
I have attempted to restore, but it won't let me for the same reason.
On a couple of occations it starts to sync!!  however it goes through practicly the whole syncing process (12,000 songs, heaps of videos) and then just freezes up! The little rainbow orb spins forever until i have to force quit.
I have had my old ipod and my partners ipod regestered and used on the one itunes with no complications whatsoever, our old ipods sync perfectly with no problems at all.
very frustrated.
Is it my Ipod Box?
Or is it Itunes?
or does it not like me having more than two ipods registered?
with the last new ipod which was replaced and the current new ipod that's a total of 4 ipods regestered on the one itunes
My partner has a Dell Laptop with Microsoft.  I downloaded Itunes on there, ripped one cd, formatted the current new ipod, and it synced the one cd i ripped with no trouble at all.
Has anyone else had the same problem with their Ipod Classic?
Mick

Is iTunes up to date (10.7)?  Have you tried plugging the iPod into a different USB or using a different USB cable?
I would recommend doing a disk diagnostic on the iPod's HD using the instructions given by turingtest2 in this older thread to check your Hard Drive's health.  He always covers what the resulting numbers indicate.
https://discussions.apple.com/thread/3784647?start=0&tstart=0
B-rock

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