Thanks for the input.
We've tested all of them once again.
All my podcasts are compressed the same way and the same go for Carl.
I completely erase 3 different iPods (including one which has the same specs as yours) and then re-sync them using the latest version of iTunes and Quicktime, All were successful.
I'm not sure what else I can do on my side.
I don't suggest that you'll format yours, but I can't see the problem here.
May I suggest that you'll try to sync once again with the new episode coming up tomorrow and let me know if it works.
Eran Stern
e-mail: stern.eran [at] gmail [dot] com
www.sternfx.com
Creative Cow After Effect Podcast
Motion Design with Adobe After Effects