2) I noticed that I can't screw the facia to the unit as hard as I did before because then the FF/next button gets stuck. This was never an issue with my 10gig. No biggie, since it's easily fixable by loosening the botton left hex screw.

Maybe you can't screw it on as tight becasue it holds more music in the same volume of space as the 10Gb.
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Dave Clark Georgetown, Texas MK2A 42Gb - AnoFace - Smoke Lens - Dead Tuner - Sirius Radio on AUX