It seems that at least two 'tool related' issues seem to be present.
fdisk 2.11g doesn't reliably establish the geometry of certain SD cards, that has been observed with 512Mb SD cards (original thread under Linux Issues - 'Hmm, could this be the problem with SD cards...').
Furthermore there is a definite issue with version 1.19 of e2fsck if you ever have to legitimately check an ext3 file system. Normal operation of this version of e2fsck, following a dismount will probably just say that the file system was dismounted cleanly, however a forced check of the file system with this version will, if allowed to, strip the journal from the ext3 file system because it doesn't correctly identify the inode pointing at the start of the journal.
Now why would that happen ? a couple of possible reasons.
i. Cards ejected whilst Z switched off and not marked as cleanly dismounted.
ii. ext3 defaults to an fsck every 20 mounts or 180 days (or there abouts) which could cause the errors to occur.
Before giving up on the card completely I would suggest that you try the tools on the 'new versions of fdisk...' thread on the Sharp Forum. Please, please report any findings that you have with the tools there.
Regards,
- Andy