Video playback pauses/loses audio

I bought a 60GB 5G iPod in December. Used it without issue for a month. Then it completely died (blank screen - nothing). I sent it back and got a refurb replacement. I copied over all my audio/video to the new one and now have an issue playing back video.
I'm using MPEG4/XVID, 320k, AAC audio, 320x240 videos I encoded with ffmpeg. Note that these files worked flawlessly with the first iPod I bought (before it died).
The same files copied to the replacement iPod play for about 15 seconds, then pause for about 5 seconds, then resume playing without audio. The only way to get the audio back is to scan in either direction then resume playing.
I called for repair. I sent in my iPod. I got it back several days later with it reformatted and a note saying they didn't find anything wrong so they just sent it back. I thought maybe the reformat fixed something but it's acting exactly the same way.
Has anyone else seen this? Is there anything I can do? Am I doomed to never play video with my video-enabled iPod?

Brad..mine did the same thing and I received help here with the following message from Dre...
This problem has been occuring especially with the 60gb iPod's. The best solution to this problem is to downgrade back to version 1.0 considering that you recently purchased this product your iPod probably came with update version 1.1 I have instructions on how to downgrade back to version 1.0
Here are more detailed instructions on how to go back to 1.0, espescially if you bought your iPod in the last couple of months and it came with 1.1.
First, please download the older version of the iPod Updater here...
http://appldnld.m7z.net/content.info.apple.com/iPod/ww/win/061-2225.20051128.PDW nw/iPodSetup.exe
Now install that updater and restart your computer.
Now open the iPod updater (Start-->all programs-->iPod and find the iPod updater you just installed
Open the iPod Updater and connect your iPod. With that older version of the iPod updater you just installed, restore your iPod by clicking restore.
The iPod will restore and go back to software version 1.0. Now reload everything back into iTunes.
It does wipe everything off of your IPOD..but if you still have it in ITunes or on your harddrive...you're ok.
Also keep in mind that whenever you hook up your IPOD from now on, it will prompt you to update to 1.1 again...just click cancel to decline and keep on keeping on!!!
Good luck!

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