50 minutes - 2 hours
The HDD of the iPod started to fail. Synchronisation was not possible any longer. The HDD started to make noise too.
As expected open the case was the biggest challenge. Once the iPod was open the rest was strait forward.
If you attempt to open the unit for any repair, think what else needs to be changed. Get all the parts and only then start the work. It is really hard to open the unit. So you don't want to do this twice in a row.
iPod Classic Color Display
iPod Classic 160 GB (Thin) Hard Drive
Rotary Tool Accessory Kit 100 Pieces