nstinson , It is virtually impossible to wipe out the mp3 players firmware or 'operating system' from a simple format because it resides on a separate chip. It sounds like the memory may have a few errors not detected by windows.
Give this a try: Plug it in and run scandisk on the player. Then format it using the Mp3 Player Disk Tool. The format with the disk tool will also determine if the memory in the player has been hacked or not.
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