I have the same problem. My Zune80 has been great since november. Now I can get about 1269 songs on it, after that the
Z80 just hangs on any further Syncing. Now I have to come up with a cool story to tell the Apple Wonks at work where my Zune is. Tech support is sending me a return label so hopefully the can get it repaired. I suppose the HD is on it's last legs. Too bad Microsoft does not have any tools for the HD since an 80gig HD could use a little maintenance from time to time.