Windows 7 and iTunes doens't recognise iPod Classic 80g after wipe clean hard drive and format fat32.

My iPod Classic 80gb every now-and-then goes funny, and eventually iTunes doesn't recognise it. In the past I could put it on disk mode, and do a reset, but some times I would have to format (FAT32), uninstall and reinstall iTunes, so it would work. Now it happened again, this time wiped clean the hard drive and formatted. However windows 7 and iTunes still doesn't recognise it. Tried many tips online but nothing works. All software I have used don't see the hard drive, so can't format it again.
I can get it on disk mode but even then windows and iTunes don't recognise it. When connecting to laptop my machine goes boiling hot. Left it connected with iTunes on for few hours but still no luck.
Any suggestions?

Hello @turingtest2.
Following your threat I realized it was time to have my hard drive changed. My iPod classic has a Samsung Model: HS081HA, 80gb/3600 rpm (real hard to get it open and check out!!!).
My question is if I DO HAVE to buy exactly the same hard drive, or I could get away with another manufacturer and model, such as Toshiba (80 GB MK8009GAH FOR iPod Video 5th 5.5th iPod Classic 6.5th 7th Gen Hard Drive - Ebay listing)?
I ask you that as these Toshiba hard drives are considerably cheaper.
Help much appreciated.

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YAY!
I didn't try shift-start of iTunes, but I DID GET MY PLAYLISTS BACK BY FOLLOWING YOUR OTHER ADVICE:
I went to my external hard drive, went to my backup at Users / Owner / My Music / iTunes / and searched for library.itl
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When I opened iTunes, ALL MY WONDERFUL PLAYLISTS WERE THERE!
THANK YOU SO MUCH FOR SOLVING THIS FOR ME!
CAN YOU IMAGINE HOW DISAPPOINTED I FELT WHEN I BELIEVED THAT I HAD LOST ALL OF THE PLAYLISTS WHICH I HAD CREATED OVER THE YEARS? Many of my playlists were composed of whole albums whose songs I had added to iTunes.
THANK YOU AGAIN SO MUCH!

Windows 7 and iTunes doens't recognise iPod Classic 80g after wipe clean hard drive and format fat32.

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