New iPod Video not Synching after initial Synch

Here is the history. My old iPod 20GB died last week and it was going to cost $271 to repair it. It was cheaper to buy a new 5.5 30GB Video iPod, so I did. I love it, but I have one small problem. After I connect the ipod to the computer, iTunes recognizes it and synchs all the appropriate files and settings. When the synching is completed, however, and the iPod goes back to the battery charging screen or menu, iTunes will no longer synch with the iPod. Sometimes I get an error and sometimes I don't. One of the settings I was trying to change was to only synch checked items. I would click the checkbox, and then click apply. iTunes would say it was synching please do not disconnect, but the iPod did not react at all.
I have called apple support 3 times, and the first guy said it is a harware issue and they are sending me a new one (it is going to take 6 days :P). The next two guys did not have a clue as to what the problem was.
I have restored the iPod twice. I have reinstalled Quicktime and iTunes 7.1. The iPod has version 1.2.1 on it, which is the latest.
I don't see how this could be a "hardware" issue. The iPod plays videos and music just fine. And it synch just fine in the initial connection to the computer.
Does anyone out there have any saged wisdom with regard to this issue? I really don't want to wait 6 days for a new ipod just to find out I still have the same issue.
Thanks,
Chris
Intel   Windows XP Pro   XP SP2, 4GB Ram

The Widows Media Player is junk and people often complain about DVD playback issues here.
It's a player issue.
I know there are better Windows DVD players - someone here will suggest one (I don't do windows).

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