I think you asked earlier if anyone else has had their rockboxed clip hang and drool. I have had that happen a few times just today while listening to some tunes. Possibly it has something against Genesis Lamb Lies Down On Broadway? Reboots were required (which thankfully is easy to do). I am using the 32GB card (filled with tunes) that I had in my Samsung Galaxy S2. Possibly I should re-format the card.
If it's an older card I would try that. i am certain at this point mine was hanging due to my 2 year old card being corrupt/damaged. Tried filling it and windows only copied 10gb before failing on a 16gb card even after low level format.
Its worth a try. UPS should be here in an hour.... counting the seconds S400 and 64gb on that truck!