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I have created books in the past with 150+ entries in the toc in multiple levels. Never had an issue on my Sony readers in loading the TOC. It might be a memory thing. Have you tried loading the TOC at different locations (cover, titlepage, small chapter, large chapter)? I believe the Sony will load in one XHTML file at the time. If that is already stretching towards the 300kb, it might be that it will have difficulties with the TOC.
Also, I understand your frustration, but as DiapDealer said, we must have a starting ground. You would be surprised how many 'problems' we see here on and outside the forum which in fact are not really problems/bugs but just plain errors which will turn up by validating.
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