Do you see a large difference in the Other file size from your 3GS to 4? I'd be willing to bet that iTunes knows that the i4 has a much higher res screen and is syncing a bigger album art file for each track. This could have a huge cumulative effect when you're talking about 5,000 songs.
Nope - I quoting the "audio" file size total as shown on the summary screen, and the number of songs that shows up on the device. The "Other" shows as a seperate amount on the summary screen and I'm not including that. BTW - the "other" in both are similarly sized.
I have no way of comparing the size of individual audio files to see if one is bigger on the iPhone 4 than on the 3GS. The 128 kbps conversion is done on the fly so it doesn't show up in iTuns, and the file size is not listed on the phone itself.
Does anyone else here use the 128 kbps conversion that can test for the same results? I guess I could try to reload everything into my 3GS first using iTunes 9.2 to see if that's the culprit, then convert it to 4.0 to see if it's that, but that would take me 2-3 days to do because the conversion process is so slow.
Tony