Ah! so glad to find this forum and this post, because this is exactly what I've been suffering from for some time on my Sansa c240 with RB 3.3.
I absolutely love the Rockbox and have been prepared to put up with this, but now it's just getting too much. Sometimes I even get parts of other albums completely mixed in with a track I am listening to. It does seem to happen more on the longer audio books than the shorter album tracks, and I only have .mp3s of various encodings, including VBR.
I too have an 8Gb SD card, but the problem happens on both the internal 1 GB card as well as the 8 Gb Micro SD card.
I believe I may have isolated the problem to some degree. When I load up my 8 Gb card on a card writer not in the slot of the Sansa, I don't appear to get any problems.
At least this is a solution for now.
I have tried loading the same MP3 both ways, and then copying the MP3s back onto my computer. The MP3 loaded up on the card writer is normal but the MP3 loaded via the RockBox has become corrupted with this stutter. it's probably happens three or four times for every hour long track.
I don't think there is an issue with my cable as I have two and it has happened with both (unless I'm very unlucky!)
From now on I will do all of my loading via an independent card writer, but if anybody has any more ideas or a solution for being able to work directly with the 8 GB card in the Sansa without these corruptions I would be most pleased.
Many thanks indeed