A few weeks ago my iPod started freezing when synching from iTunes and always at about the 1.2Gb point in the transfer. Eventually iTunes would time out with a (-36) error message. Restore didn't work, neither did mounting the drive and using the OS X disk utilities.
However, this chap has a page that shows how to swap the firmware on an iPod by switching the contents of the second partition. Someone called "Steve" then took this one stage further and, having the same issue I had, grew partition 2 by 2Gig and, at the expense of having less music storage space in partition 3, got a working iPod back.
I did the same thing last night and it worked a treat. I had to grow P2 to 4GB - but it works - and I have about 165GB of storage space. But more importantly - a working iPod.
In the instructions I'd make the following observations (some of which are made at the bottom of the page):
1. Don't worry about backing up the firmware - the partitioning doesn't remove it. Ignore all the dd stuff.
2. Set the partition in the C P2 command line to be something larger than the point on the disk at which the error occurs
3. Do NOT use the iPod updater RESTORE facility at the end as it will set P2 back to 32MB
Other than that - it worked a treat.
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