Video works on iPod, then becomes audio -- no pattern of why...

Ok, I copy my mp4 videos onto my Ipod (video 60gb) from my Windows XP computer with latest iTunes..
The videos worked fine yesterday on my iPod.. I tried to look at them today, and they were being treated as audio files..
This is not the first time this has happened to me.. The half-assed solution is to copy the videos again from the PC to the iPod and it will fix it for a day or so, but they always go back to being audio files.. And its so random that I cant trust the video to be there when I need it now... (I'm a filmmaker and its really nice to have my film trailer with me at all times)
I've tried to reset all the settings on the Ipod
Ive made sure the "TV Out" is set to "off.
Possible problems
I manually sync the iPod music..
I use the Photo's feature (which seems to be only Automatic syncing) and I've noticed that video files usually screw up and turn to audio when Photos gets updated..
But it happens other times too.. This morning I manually re-copied all my video files to my ipod, and they worked immediately after i disconected from the PC.. Later that day (without reconnecting to anything) I was tryin to show somebody my trailer today, you guessed it -- it was an audio file... It is REALLY frustrating - especially when i bought the dang thing for this specific purpose...
Any suggestions? When it works it really is a cool feature...
Thanks
-=James

James,
I'm not sure if this help you, but it help for me. I was having problems with video files on my Ipod. 95% of the time videos start fine. After 30 seconds (more or less), audio start to fail and video stop. After a couple of seconds, video resume but without audio.
After troubleshooting my Ipod (Video 60gb), even re-installing everything again, I decide to "downgrade" the firmware. Yes, I said "downgrade". After this, all videos run smoothly and with audio. No problem so far.
I use a program "Ipod Wizard" to downgrade the firmware.
What I'm telling is that maybe is not a setting problem, maybe is a firmware problem like I had.
Als, my personal recomendation is to keep all setting to auto-syncronization. Including music, photos and video files. At the beginning I uses to sync manually but a lot of problems came up.
Remember, first of all, BACK UP everything

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