Serviced ipod comes back with a sad-face icon

Question

I recently had my 4th generation clickwheel ipod serviced, because it had a harddrive issue. iTunes had randomly failed to write a song to the ipod, whereupon the ipod decided it would no longer start correctly, or be recognized by the PC correctly. In the periods of time that the iPod would try to start back up, and while it is connected to the computer, the iPod just whirrs, then clicks and stops, whirrs, clicks and stops, over and over and over again. It was basically overheating while doing this, and thus it was rendered useless. This was the second iPod that I had, as the first one's touch scrollwheel randomly quit.
So after 20 days of this second iPod, i sent it back after a phone call to tech support that made them waive the fee.
So... now I get the iPod back, looks brand new, but I don't think they did anything to it... other than maybe swap out the case. The hard drive keeps clicking and whirring, only NOW... it won't respond at all to being plugged in with it's power adapter or the PC. At all. It just starts up with it's click and whir noises, and then shows me the sad-face icon.
please, nobody tell me to use the ipod updater to restore the ipod, and nobody tell me to try resetting the ipod via the hold switch and then the menu and select buttons. You can trust me that I've tried all the typical ways of making the iPod do what I paid $360.51 to make it do. But no.
What I am curious of, is...
Is there any way to have the iPod get back on it's feet, without sending it back in? I've literally had it for 2 days, waiting to bring it back home so that I could begin putting my music back on it, but when I start it up for the first time, it does this to me, and I can't connect it to the PC. I know that the iPod starts off being mac-formatted, but last time, it would at least TELL me that, and ask me if I wanted to format it for the PC environment.
Is there any self-help hope? Or should I just call tech support (AGAIN coughcough) and become another disgruntled customer?
I'm a patient guy, and I understand that tech gadgets have issues sometimes... but dang. If I in fact service this iPod, I'll be getting my 4th one in hopes that it will work. I'm willing to try some random crap in order to make it work?
Any idea for random crap that I could try?

Answer 1

hehe, yeah, i meant to come back and update the topic with what i'm doing
I called apple tech support line again and went through a normal process to figure out the issue.
well..
they tell me that i can only use this line once in order to have it serviced, so he's not sure he can do anything since i've already "used" my one service request.
well, i'm all over that. i told him my issue anyway, giving him the dumbed-down version, which is "hey, you sent me a broken ipod" or something like that. so, he's setting up the box the be shipped to me and was going to charge me the $31.50 or whatever, but i threw a dignified fit over that, since, well, it's THEIR problem that they sent me a busted piece of sillyness. anyway, he puts me on hold after waiving the charge, but another guy (a "product specialist") picks up my line and reviews the problem with me.
okay, here's the climax of the story
he tells me that since i've been having so many fatal issues with the ipod that renders the hardware useless, they are going to upgrade me to an updated model.
I was happy, but i was thinking that they were going to send me on my way with a 40gb or something.
nope.
(it's better than that)
he told me that since they don't make the model that i currently have, they're going to send me a 20gb photo ipod as the replacement product.
had he been standing in front of me i would have tried to hug him or something!
so, my efforts have been muchly worth it, though, there's a bit more of a process you have to go through. the tech asks for your info, like address, email, yada yada, and he gives you a case number. then, 2 or 3 days later i got an email containing a link for an online shipping label that i had to print and slap onto an old service box. i had to send the ipod to them, but then call back the rep and give him my case number and tracking number. i'm currently awaiting some sort of confirmation over the issue, but he's told me earlier that once they confirm that the ipod is contained in the package and that it is in fact on it's way, they'll have the apple store ship me a brand new packaged 20gb photo ipod.
if at first you don't succeed, try try again. and again. and again. and one more time for good measure.