So the pending sectors aren't cleared. You may need to repeat the erase/restore process a few times to clear all the pending sectors. You could try formatting as MS-DOS/FAT which will make iTunes reformat as Mac OS Extended (Journaled) when it restores. Switching between the formats might help with the conversion of pending sectors into reallocations. After restoring but before adding any media check the stats again. No point trying to add media until pending is zero.
From the user tip:
Break up large transfers
Once you've restored your iPod don't rush to dump all the data back exactly as it was before. I have found that lots of large or complex smart playlists can sometimes trigger constant reboots or dumping of the iPod's library. In addition, larger transfers can fail leaving data in an inconsistent state. Try this technique for populating the iPod in stages.
In iTunes select the menu item File... New Smart Playlist. Change the first drop-down box to Playlist, the next to is and the next to Music or whatever playlist holds the bulk of the content you want on your device. Tick against Limit to, type in say 10, then change the drop-down to GB, and set the last drop-down to artist. When you click OK you can enter a name for the playlist, e.g. Transfer.

Now sync this playlist to your iPod rather than your entire library. When the sync is complete modify the rule (File... Edit playlist) to increase the size by your chosen amount, then sync and repeat. You can experiment with different size increments, if it doesn't work just choose something a bit smaller until it works each time. Before long you should have all the music that you want synced added to your device. Once that's done you can move on to other media such as podcasts, videos, photos, additional playlists, etc.
tt2