I had posted another response prior, but having had my memory refreshed somewhat after seeking a second opinion, everything here is pointing to your host system and/or iTunes being at fault. In this state, no Rockbox code is running at all. iTunes most certainly can recovery your device from this state, it failing to do so indicates the problem lies on the host system. You may want to try some of the simpler things first, such as:
- using a different USB cable
- using a different USB port (fron panel USB ports are almost always giant pieces of crap)
- uninstalling/reinstalling iTunes and its device drivers
-
downgrading iTunes (we have had success with 9.2.1 in the past for the iPod Classic (6/7G) when iTunes has failed to restore)
Out of interest, what made you believe you needed to format the device? Am I to assume you had a Mac formatted iPod (in which case formatting the storage volume alone would /probably/ be sufficient for Rockbox but the Apple firmware would freak out about it).
[Saint]
EDIT: added link to assist downgrading iTunes