Thanks for the info.
pmcdonald wrote:Well, I read all the information that was available where I obtained it. (
http://hddguru.com/software/HDD-LLF-Low ... rmat-Tool/) The only warning (I saw) there (even after rereading) was that it would erase my data - a pretty obvious outcome of formatting.
[
My bad - I see it's recently been updated, and I hadn't noticed, sorry.

The program used to be incompatible with Win Vista and later versions, hence my concern...
pmcdonald wrote:In the mean time, I am using the utility because windows in unable to successfully (low level) format the drive (not fully - it hangs around 25%).
Windows can never do what is accurately termed a low-level format on a disk (i.e. rewrite the AM & DM on the disk service) through its normal functionality. A low-level format on flash means different things to different people, since the
original meaning of a "low level format" on a disk, cannot apply to flash. I guess you're referring to trying a full format which on Win Vista & later, will write to every block in that filesystem.
As I'm not the author of HDDLLF, I don't know exactly what it does - but on any attached USB device (like yours), it's severely limited as to what it can do in order to "format" a disk, other than write to every block (due to limitations in the USB Mass Storage Device protocol). Writing to every block is exactly what Win Vista would also be doing for a full format, as I explained above (although things like number of retries etc. could be different, and hence you might see different results).
Regarding your original question (mis-reporting drive size), I can only suggest requesting support via that new contact form linked to the HDDLLF page, but unless you have paid for a license, I don't know if support is offered. Also, this could be a side-effect of faulty hardware or, to say it another way, this
may not be an HDDLLF bug.
If I was in your situation, I would be looking at the Windows Event Log, to see what errors it was logging when the attempt at a Windows full format hangs, but I would not expect that any software (inc HDDLLF) can fix a problem with your hardware, which seems to be what you are describing.
Good flash controllers are supposed to retire faulty NAND blocks (up to their limit of spare blocks) which are detected during writes, so if yours isn't doing that, normal PC software isn't going to fix it, as the PC doesn't (can't) control what is happening at the level of this type of flash - perhaps your iPod has already reached its limit of spare pages... (Some flash controllers have specific PC utilities which can be used to force them to test their attached flash via vendor-unique USB commands, but I don't work with iPods and so don't know if such PC software exists for you.)
Have you successfully used all 160GB on this iPod for a while, and only noticed problems recently? Some history of events leading to this point may help to better understand likely causes - or you can just keep running HDDLLF and see what happens.
Sorry I can't suggest more to help you at the moment.
P.S. Thanks for your subsequent post, and I now see that you weren't missing, what I thought you were missing - as I said, I was starting from obsolete knowledge of an older version - my bad.

That's what happens when I rush to reply before I go to a meeting, and don't do my research first! Sorry again about that. Hopefully other members will have more suggestions for you!