my 160gb ipod classic will not respond

If the iPod is powered on, force shut down the device, firmly turn off the hold switch, then press the center and menu buttons simultaneously until you see the Apple logo. If the device is powered off and not charging, try using a FireWire to Dock Connecter cable, FireWire outputs more power than USB and is useful for this purpose. If neither works try putting the iPod into recovery mode, first, if you have important music on the device, try using Disk Mode, press and hold the play and center buttons and plug in to your computer, in Finder preferences, enable hidden files, copy your music over to your computer. Windows should have a similar process. Then, delete the iPod in disk utility. Restore your device using iTunes.

See also Corrupt iPod Classic - Apple Community. Are you able to get into diagnostics mode? If so what are your HDD stats?

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