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Could be the card itself. Try a different card. I actually use two cards (in addition to iPod) and both cards are 16GB, Class 6. Perhaps you're using a card that is too fast (or too slow) for the unit.
 
Not sure this will make a difference, but I bought the Mac App 'Playlist Exporter' to move iTunes playlists to my SD card. It's $4.99, I think.
 
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