[iTunes] Ipod wont take songs

[HSM]

My ipod, 40GB, was working fine, then suddenly there was a display of  
corrupt file on the screen. I restored it using the latest ipod update .
Now when i tried to sync with my Mac OSx10.4.7 , it only took about  
187 songs out of the 6500.

on a second attempt to sync it only took fewer songs

i restored it again ,  now it takes about 10 songs

there is no abnormal sound of the internal ipod disk or anything
the software seems working great

what could be the problem and how do i fix it.?
thanks

Sam