Could you please say what version comes back with ...
fdisk -v
# which fdisk
/usr/sbin/fdisk
# fdisk -v
fdisk v2.12a
#
It's looking at the right place, and I installed the fdisk at the beginning of this thread... so hopefully that should be the correct version.
# fsck.vfat /dev/mmcda1 -a -t -v -V -w
dosfsck 2.8 (28 Feb 2001)
dosfsck 2.8, 28 Feb 2001, FAT32, LFN
Boot sector contents:
System ID "mkdosfs"
Media byte 0xf8 (hard disk)
512 bytes per logical sector
16384 bytes per cluster
1 reserved sector
First FAT starts at byte 512 (sector 1)
2 FATs, 16 bit entries
126976 bytes per FAT (= 248 sectors)
Root directory starts at byte 254464 (sector 497)
512 root directory entries
Data area starts at byte 270848 (sector 529)
63359 data clusters (1038073856 bytes)
63 sectors/track, 32 heads
0 hidden sectors
2028032 sectors total
Starting check/repair pass.
Checking for bad clusters.
Reclaiming unconnected clusters.
Starting verification pass.
Checking for unused clusters.
/dev/mmcda1: 6 files, 0/63359 clusters
#
That means that my Zaurus was able to read and write (at a low level) to and from every single bit on the MMC card, I assume. It also means that it couldn't find any problems with the card, right? (Assuming I'm reading this right... if there WERE problems, I assume it would display them here.) That would mean that the card is fine, and I don't need to worry about returning it, and the problems are os/application related (is that correct? ....I worry since I hear so many stories about bad SD cards... and I got this one for so cheap... I worried that it may have been a dud...)
Above, in the fsck output, it says "2 FATs, 16 bit entries". What does that mean? I thought FAT was the information at the beginning of the partition... how coukd I has 2 of them? ...is one of them a backup copy, or does it indicate that I have 2 partitions with FAT16 on them?
Since I had previously ejected and reinserted the MMC card, I tried my mkdir test again...
# cd /mnt/card
# ls
Documents Install_Files test
# mkdir test2
# ls
#
I think I might be on to something here... The "test" directory I made last night is there (which means it actually wrote it), but when I tried creating "test2", they all disappeared again. Here's what I suspect might be happening (let me know what you think): When the Z writes to the card, it write the data, updates the main FAT but then has problems updating the backup FAT (FAT #2?), so it sits there waiting for something... but when the card is ejected/reinserted then the data and FAT #1 are still there and working fine... until something else needs to update the data and both FATs.
Does sound like a good theory? Would that imply a problem in mksf in how the backup FAT (FAT #2) was created, or would that mean there's a problem with how Linux on Z is writing to the FATs?
Has anyone out there succesfully tested VFAT on a 1 GB MMC on your Zaurus? Maybe this bug only happens past the 1 GB barrier... (should I try repartition to 900 MB and 100 MB partitions?)
Should I try the "Win95 FAT16 (LBA)" instead of "FAT16" (#6)? ...or how about any of the other FAT16 cousins on that long list?
Thanks again for everyone's help so far!