Multiple 160 GB iPod Classic issues

Last August, I purchased a 160GB iPod Classic. For the first several months, it worked just fine. I hooked it up with the audio cable and it would play in my Hyundai Tucson. One day in the Spring, the volume stopped working in the vehicle. I tried other cables and reset the device several times. It started to work again. About a week later, nothing. It wouldn't even have sound when hooked up to headphones.
I took it the Apple store and we tried it out in a vehicle of one of the associates, it worked. Took it home, down again. Had it replaced. Tried it all different wasy, bought a new audio cable for the car, headphones, etc. NOTHING. Had it replaced last Saturday for the second time. Used it everywhere but the car and it worked. Yesterday, I put headphones on and it crash. (Did not try in car yet).
My questions are these: I have a 30GB Classic that has the same library on it. Could there be something wrong with the library? Corrupt? Could the vehicle need a certain something installed? My dealership knows nothing. I've searched online forums for the issue (thinking maybe it was the car). But this one didn't even go in the car and it crashed after a full charged and library sync.
In case it matters, I have a MacBook Pro 13inch using the most updated iTunes and software.
If anyone can help-Thank you!

Also, I am using my older 30GB iPod classic and it works fine with all outlets, headphones, vehicle, etc.

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    Message was edited by: rezzzz

    Yeah- that sounds very frightening indeed. I also have the 160GB iPod Classic black but it purs like a kitten. I've had problems with the battery meter not being accurate but I can deal with that. I hope you have it insured with an extended warranty like I got when I bought it at Best Buy last year.

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    * don't play any games if you wish to synch your playcounts/ratings with itunes. Playing games causes all changed playcounts/skipcounts and ratings since the last synch to disappear. THIS really annoys the **** out of me and I really(!) hope it will be fixed soon!
    * cower flow takes a little to load your album art - and it needs to load it again every time you enter it. at first I thought it does not preload the album art at all, but I noticed it just takes a while. this can be a little disturbing, because you see only "empty" albums at first, and they take a few seconds to load.
    * for some reason you cannot brwose music videos by artist. it's just one long list.
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    Message was edited by: m8an
    Message was edited by: m8an

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