iPod: Disk Utility erasure for synchronizing problems

We've reported on an issue where iTunes crashes shortly after an iPod is connected several times. Previously noted solutions include removing all other external peripherals - particularly FireWire devices other than the iPod; and s deleting streaming references in the iPod master library (streaming references include iTunes' radio stations and other streaming source files).

Now MacFixIt reader Bill reports that performing a reformat of the iPod's hard drive in Apple's Disk Utility (located in Applications/Utilities) can sometimes work as a last-resort option before sending the unit in for repair. He writes:

"In this first failure iTunes simply locked up, displayed the rainbow pin-wheel of death, and required a force quit of iTunes. [...] So I reset the iPod. Reconnected the iPod. iTunes locked up again. Disconnect, reset iPod, launch iPod Updater 2004-08-06, restore iPod. Disconnect, reset iPod, re-connect, iTunes asks to name iPod (update automatically is checked), iTunes begins to transfer songs but soon reports 'Attempting to copy to disk 'iPod' failed. An unknown error occurred (-36).'

"Over the next two weeks I try various combinations of iPod resets and restores. I even get Disk Utility and DiskWarrior to check the iPod after being freshly restored. Neither program reported a problem. I installed a squeaky clean 10.3.5 without the Sept security updates on another freshly reformatted internal disk, with the latest iTunes, latest QuickTime, latest iPod updater, and permissions repaired. Still no success, iTunes continued to lock up or reported 'attempting to copy disk failed.' A simple restore whether or not the iPod was in 'Disk Mode' did not correct the problem. Very frustrated, I pulled out the iPod's warranty booklet. But wait, lets try one last thing before calling Apple...

"The Solution: Reformat the iPod using Disk Utility, being sure to use 'Mac OS Extended' and in 'Options...' check 'Zero all data.' Before doing so, it is necessary to put the iPod into disk mode (see Apple Article 93651), otherwise iTunes will try to launch when the iPod is connected to the computer. It takes a long time to reformat when "Zero all data" is checked. In my case, it took somewhere between 30-60 minutes to reformat. The progress bar moves very, very slowly and I would put the iPod next to my ear just to be sure the disk was still spinning. Now with a completely reformatted and zeroed iPod, disconnect it (being sure to Eject it first!), launch iPod Updater, reconnect iPod, and hit Restore. Surprisingly, the iPod was still in Disk Mode after going through this exercise, so I reset it. Connecting it once again to the computer, iTunes launched, asked for a name, I left checked the "automatically update" selection, hit OK, and to my great relief the transfer of my entire iTunes library completed without a problem. Hurray!"

Feedback? Late-breakers@macfixit.com.

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