You are welcome, but I see you only tracked the hanging issue.
I have feeling that also without any iPod activity just a startup of MM with the iPod connected already leads to endless error messages.
Please check.

And if you can, please have a look at my previous TWO posts with numerous iPod syncing issues/questions/remarks.
Didn't get any proper reaction yet.
Thanks, goodluck

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Tracked as: http://www.ventismedia.com/mantis/view.php?id=8517

Since I installed release candidate 4.1 today (build 1445) I have not been able to use MM normally.
At the first startup the font was superbig, later I found out the skin setting was set to 200% font size. Easy to change, but a strange default.

After that every time I started up MM with my iPod attached. Never successful. There was a constant range of error messages - check your inbox, I sent many.
Often after such message MM completely hang and could only be terminated with taskmanager.

A few times I could continue, I tried to load my iPod contents, select all 24.000+ songs and completely remove them from my iPod. Because after the latest sync I found out that from the 24.000+ tracks many did NOT work: they SEEMED to be copied to the iPod, but maybe only the titles were copied - not the files. Playing them was impossible, the iPod often hang.

But in MM selecting ALL 24.000+ iPod songs took ages and often did not work at all. One time I got the message 'Do you really want to remove the 24.000+ tracks from your device' and after I clicked YES the program hang.

I sent my most recent debug file (just a hanging startup) to rs and ls, please check your mailbox and download via WeTransfer, as usual.