This took a ridiculous amount of trial and error and looking for clues in this forum, but I finally managed to sync playlists onto my Clip Zip's sdhc card using Media Monkey. This is what worked for me -- I make no promises that it will work for anyone else.
1) First, make sure you are able to sync to your card at all. I had to try three different cards before I found one that worked with my device. Fortunately, my Sansa Fuze and my phone were less picky, so I had different cards to try. The one that worked was a Sandisk 16GB Micro SDHC, Class 2. If you can't even sync music, the problem may be your card.
2) Downgrade your firmware to version clipzip01.01.12. I could not get it to work with the current version.
3) Open Media Monkey. (The basic version is free.)
4) Connect your device. The device should show up in the tree in the left-hand column of the page. The device and card will be listed as two separate devices. Click on the listing for the card.
5) Media Monkey should take you to a Summary page. In at the top of the center cection of the screen, click the "Auto-Sync list" and select the playlists you want to sync.
6) Under options, click "Playlists".
7) Check box next to "Sync playlists."
8) Under "Generate device Playlists for", click "Library Playlists."
9) Under Destination directory, enter "Music\Playlists\". (No quotation marks.)
10) Check box next to "Force relative paths." Leave other boxes (e.g., "use unicode ...", "use extended M3U", "Use Linux folder separator") unchecked.
11) Click "Apply" to save your changes.
12) Right-click on the device and select "Auto-sync" to start syncing.
Unfortunately, playlists that were more than 1,000 songs were cut off at the 1000th song, but otherwise, it worked great!
I hope this helps somebody out there.
