Update to 1.2.3 bricked 60 GB iPod video - strange things in disk utility

In brief - my wife hadn't updated her iPod in quite a while. It's been pulling nursery duty for the past year. She wanted to switch out some music, so she connected the iPod to her laptop (Powerbook running OS X.4.9).
We updated to the latest iTunes. Were prompted to update the iPod to firmware 1.2.3, then the trouble began. Update ran, files started to transfer, then everything locked up at about 2GB of music moved.
Went through the 5R's. Got in to the restore loop that so many other 1.2.3 users have found themselves in.
Decided to poke around in the file system and also to try a disk erase.
Disk Utility is showing the iPod as a 2TB drive (yes, it thinks it is two terabytes!) No option in Disk Utility will work. Tried to partition (thought it would re-write the partition table). The attempt fails with the following:
[task] failed with the error:
Input/Output error.
Now here is where it get's trippy. opened up a Terminal window and ran through some command line steps -
disktool -l reports a drive as disk 2
*Disk Appeared ('disk2',Mountpoint = '', fsType = '', volName = '')
pdisk /dev/disk2 yields this
Partition map (with 512 byte blocks) on '/dev/disk2'
#: type name length base ( size )
1: Applepartitionmap partition map 62 @ 1
2: Apple_MDFW firmware 196608 @ 63 ( 96.0M)
3: Apple_HFS disk 117013560 @ 196672 ( 55.8G)
Device block size=512, Number of Blocks=117210240 (55.9G)
DeviceType=0x0, DeviceId=0x0
So the file system appears to be there, but is totally munged up in such a way that all of the GUI tools are not able to access it.
Tried to zero-out the drive using disk utility (one site suggested this had worked for a bricked iPod) but it didn't work. Now the pdisk doesn't even report a partition map to work with. Things keep going from bad to worse... and I started at terrible.
Does anyone have any pointers on what to do next to get a this thing working? Or is it time to invoke my wife's applecare?
Thanks in advance, bill

Hi, I have the Logic3 Universal Dock, using S-Video and stereo line out for Photos and Videos with sound to my TV, which works well.
BUT NO MUSIC when I want to play just music through the TV! Is this a software issue? You say you used to be able to hear music through your TV. Apple please help here! Thanks.

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