Similar problem:
"The format did not complete successfully"
I have (or maybe had !) a 4gb SD Transcend (normal speed)
While trying to copy map files the card dissappeared from my x51v.
I formated it in an external card reader.
I tried to copy files again and it dessappeared again
Now, while trying to format it in the reader, windows start format and at 100% says "The format did not complete successfully".
I'm going for a 8GB CompactFlash card now, since 4gb SD is NOT A STANDARD (check
http://www.sdcard.org/) and dell can not read HCSD cards