Rrrreaaaaallly.... I never heard of Hijack causing sync issues...

Well, I have, specifically on my box. I get errors during sync really similar to what you get, except it's ALWAYS during the deleting database step. If I shell into the player and rm -f /drive*/var/database the same thing happens. Of course, when this happens, I can't sync again without a long fsck. Of course then it just happens again...

One thing I've noticed, though, is that flashing the stock kernel makes it work every time. So, whether there's a bug in Hijack or having Hijack just makes memory tight in such a way that my player chokes, I don't know. I'm not running anything besides Hijack, though.

This most recent time that it happened, instead of flashing the stock kernel I set ReserveCache=64 and synced again. It worked that time. I don't know if that's just coincidence or not. If I really need to reserve cache, I hope there's a saner value than 64 that works for me.