Sync Problems for Second Ipod

I bought a 60Gb iPod last year so that I could listen to my music during my 80km round trip to work. It was so successful my wife nicked it ! Bought an 80Gb version yesterday but cannot load my iTunes library to the new kit.
It will part load, the gives the error message "attempting to copy to the disk *** iPod failed. The disk could not be read from or written to".
This usually happens after about 2.5GB have downloaded, but on the first attempt 7.4Gb transferred successfully.
What am I doing wrong ? Please help someone !

Hi Capinrage. You should be able to copy the entire content of your wife's 2Gb iPod, let alone one or two tracks !
I found something similar when I started to copy to my new disk. I use a firewire connection for the 60Gb iPod, but can only use USB for the 30Gb model. When I was trying to work out what was wrong, I tried the 60Gb Ipod on the USB connection but iTunes wouldn't recognise it at all. Eventually changed the USB port and that worked so it might be worth trying.

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