I have the exact same problem: For the last two weeks, my video iPod and iTunes are inconsistent in the song count. iTunes shows 10,785 songs and videos (237 videos) on my video ipod. Clicking on the ipod icon in iTunes also shows 10,785 songs and videos. But on the iPod itself, under "about" it shows 10,596 songs and 237 videos. There are only 10,548 songs however, and none are duplicates in iTunes.
I also have a 60 GB photo iPod with all the songs (but no videos, of course), and both iTunes and the iPod itself show that there are 10,548 songs on the photo iPod. That one is fine (but of course, it hs different software running it than the video iPod.
I have deleted and reinstalled the latest QuickTime and iTunes applications, and I have also done a complete wipe and restore on the video ipod (twice!), then re-synced. Because my PowerBook only has USB 1.1, it takes 18+ hours, and at the end of all that, the iPod still shows the "extra" 48 songs.
Every song in my iTunes is in at least one playlist. I checked playlist by playlist, comparing the video iPod to iTunes, and the playlists all match up perfectly. I have also checked for duplicates - I have none. I can't figure out why the settings screen on the iPod shows 48 more songs!
I also saved as .pdfs of both the video ipod and iTunes song lists, and compared them. They are identical.
The Mac tech suppot people have not been able to tell me anything beyond, "well, it doesn't seem like it's that big a deal."
It isn't a big deal,but then, I'm not being paid to fix this stuff - they are.
12 PB G4, 80GB HD, 867 MHz Mac OS X (10.4.3)