This does sound like a faulty drive cable (email me your address and serial number for a replacement) or a dry solder joint on the IDE header (you'll need to send the player in for service in the new year).

If you suspect a software problem, get a boot log. If it points to a sotware issue, then a drive rebuild would be the easiest solution.

Drive cables are the culprit in 90% of cases, but the problem only affects about 10% of players.