Sorry, to just to be clear, I have the most recent (and will always have, because I'm anal about things like that, for future post reference) everything....MC version, iPod plugin, iPod firmware, etc.
I discovered that my problem (I', 99% sure at least) was that I had made changes to the files in MC (either tag changes or file renaming from within MC) after the files were added to the playlists that I sync, but I had not run an "Update Library" process. Upon several syncs, MC would lock up on one song and I would have to literally hold the power button on my PC for 10 seconds to turn it off because nothing (and I mean nothing) worked to end MC ro the sync. I would then have to reset the iPod (while still docked). Out of curiosity, once my PC rebooted, I dug around the /iPod_Control/Music folders and discovered that in folders F02, F05, F07, F15 and F19, there was, in each of said folders, one track that did not have any tag info (and each track's name, i.e. 15260.mp3, 15261.mp3, etc. was a consecutive number). If I right-clicked said tracks, unlike the tracks that did display tag info in Windows XP explorer, the properties summary (and advanced info) had no information about the track other than it was 2 channels and 44.1Hz. Because of no tag info, and because it was at 5:30 this morning, I could not figure out a way to determine what the actual tracks were (I tried to compare file size of tagless tracks with file size of tracks in synched playlist, but couldn't seem to find matches...or maybe I'm just blind...hmmm unintentional archane reference to 3 Doors Down lyric). Anyway, I just said f__k it and cleared my library, did a re-import, created my playlists again (didn't want to import saved playlist for fear it would hold corrupt info and was too lazy to examine playlist in notepad), synched w/ ipod and everything worked fine.
I wish to God that MC would auto update the d__ned library after tag and/or file info changes instead of making me remember to "Update Library" everytime. Maybe once I get all tags and filenames in order it won't be a big deal, and maybe that's what they assumed when they didn't make auto update a standard feature, but right now it's a pain in my a__.
Hope this helps others with similar problems...
Wobbley