Re-Building Library Failure/Firmware Problem on X

Hello,
I am experiencing a serious problem with a Zen Xtra 60gb. Last night when my brother booted up his player it went straight into 're-building library', not a completely uncommon experience, I know. However, this prcess failed to complete and stuck around /3 of the way through before moving to a 'Firmware Problem' screen.
Having searched through various forums I tried a few tricks:
Firstly, of course, I reset the player with a pin.
I booted into recovery mode and tried a 'Clean-Up'. This strangely cleaned 400% of the player before completing.
I also tried removing the OS and replacing it again. It is the latest firmware version.
None of these things solved the problem.
Therefore I would be very much grateful for your advice as to solve the problem, hopefully without losing the data. If at all possible, I would much appreciate someone sending an earlier version of the firmware to see if that works (currently using .20.08 ).
Windows XP currently detects the player, but presumably none of my software will work without the Firmware installed, but if someone could maybe point a way to back up the data on the player in a current state, we'd be extremely grateful (yes, I know he should have done that already).
Of course I'll ring Customer Support first thing tomorrow, but I'd love to get this solved quickly for my little bro as he's spent quite a lot of time getting everything he wants on the player and makign playlists.
That was one long message, but I wanted all bases covered. Thanks in advance...

See "firmware problem" in the FAQ post.
If you've tried everything there and still get the error then the player is faulty and needs to be replaced. Contact Creative via the Support > Contact Customer Support link on this page.

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