I have Sansa Clip+ with the newest version of Rockbox (I've just upgraded to the latest release) and have the following problem with the SD card.
When I insert the card for the first time, Sansa recognizes it and lets me play the files. When I remove the card and reinsert it, the player no longer recognizes the card (behaves as if there was no card inserted). First it happened while I was using Rockbox 3.9 version, so I upgraded to 3.12, after upgrade Sansa recognized the card, then I checked what happens after removing card and reinserting, and wham! - the problem reoccurs.
I checked two different cards, Sandisk and Kingston, both 2 GB, the same problem with both. PC has no problem with both cards. I tried to format the cards (via PC), does not help.