Problems... Not sure if its hardware or software.

I have an iPod Classic 160gb, running the latest firmware (1.1.1) and iTunes 7.6.1. The HDD seems to be loud and from time to time, makes a audible clicking noise. Whenever I connect my iPod to either my home or work PCs and play music off of it, the CPU goes to 100%.
2 or 3 times now, iTunes has frozen, stopped playing music. I kill the task and safely remove the iPod. The iPod appears to have hung, so I reset it (Menu and middle buttons together). After it resets, it says there are 0 songs on the unit, however after plugging it back into the PC, Windows shows all the music is there. After re-opening iTunes, iTunes proceeds to delete all the music and wipe the unit clean.
This problem has happened with different firmware versions, including the latest. There is no pattern to any of the problems (100% CPU or hanging). Being in the IT industry, I know its a bad sign when an HDD is making loud clicking sounds.
I've spoken to Apple support and they weren't very helpful. When I suggested that I will send it in for repair/replace, they responded with "If the technician tests the unit and doesn't find a problem, it will be sent back no fault found". The HDD problem is so random that I doubt it will show up during testing.
Any ideas?
Thanks in advance,
Dan

Go to this thread:
http://discussions.apple.com/thread.jspa?threadID=1458819&tstart=0
Find and follow turingtest2's post about checking ipod's hard drive for errors. Hopefully nothing is amiss with the HDD, if nothing's wrong, you could try restoring it, wiping the ipod clean then starting again.

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