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I have had similar problems to what has been described. When I had the same problem of the card not reporting correct file size I used storage tools to analyse and it said the structure was corrupt. When I went back to pc explorer now there was hundreds of 4k folders there. BTW now realise this is the size of the clusters : ). and was able to delete them. I had repeated problems after a reformat with storage tools and took it back. No problems yet. I will be erasing and reloading today to see how that goes.
My theory? On my three other crashes I was messing around while coping large amounts of data onto the card. Exploring around from the axim, monitoring the space, even installing apps. I have tried just leaving it alone to concentrate on the file copy and seems to have worked. Maybe this is the problem?
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