OK, I opened the player and reseated the cable on the MB and pushed in the connector on the hdd. I checked the solder points and they are all connected. I've not modified the kernel or added any more then the 10GB drive that came with the unit. I tried to sync again without any change. Does this mean I have a bad drive?

I also ran the manual fsck on the drive and this is what it came up with.

q
Restored terminal settings
Remounting first music partition read-only
Remounting second music partition read-only
No secondary hard disk
Player exited normally: 0
Switching to shell-player loop
Starting bash.
empeg:/empeg/bin# ro
empeg:/empeg/bin# umount /dev/hda4
empeg:/empeg/bin# umount /dev/hdc4
umount: /dev/hdc4: not found
empeg:/empeg/bin#
empeg:/empeg/bin# umount /dev/hdc4
umount: /dev/hdc4: not found
empeg:/empeg/bin# swapon /swapfile
Adding Swap: 16596k swap-space (priority -1)
empeg:/empeg/bin# fsck -fay /
Parallelizing fsck version 1.19 (13-Jul-2000)
e2fsck 1.19, 13-Jul-2000 for EXT2 FS 0.5b, 95/08/09
ext2fs_check_if_mount: No such file or directory while determining whether /dev/
hda5 is mounted.
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
/dev/hda5: 1514/4096 files (0.5% non-contiguous), 9443/16384 blocks
empeg:/empeg/bin# fsck -fay /dev/hda4
Parallelizing fsck version 1.19 (13-Jul-2000)
e2fsck 1.19, 13-Jul-2000 for EXT2 FS 0.5b, 95/08/09
ext2fs_check_if_mount: No such file or directory while determining whether /dev/
hda4 is mounted.
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
/dev/hda4: 3694/76800 files (9.1% non-contiguous), 2073144/2434320 blocks
empeg:/empeg/bin# swapoff /swapfile
empeg:/empeg/bin# sync

Thank you for the help so far.