Battery & Crashing issues with Sandisk 64GB microSDXC in Rockboxed Clip Zip

[WithARidiculousClip]

I have been using my Clip Zip w/o Rockbox and with a 32 GB microSDHC card with 0 issues for about 8 months. Then I put Rockbox on it, and once again had no serious issues for a few months. Then I bought the 64 GB Sandisk microSDXC card (and formatted it to FAT32) since I read that this has worked out for most people. And that setup worked for about a month pretty much w/o a hitch. Every once in awhile Rockbox would crash with either mem card, but as the Clip Zip doesn't have a stable build yet I wasn't very concerned, a simple reset sufficed.

But then I had the player half-freeze in the following fashion: screen timeout worked correctly, any button press would turn the screen on, animations on the screen worked correctly, no music would be playing though it should be, the progress bar wouldn't advance, any button press would do nothing. Hard resetting the player would bring it back to the same state since I have resume playback on turn on. I would remove the card, turn it back on, that seemed to bring it back to life once it realized the playlist file was no longer valid, sometimes this will take multiple resets. Playing something from internal memory would work. Playing something off the SDHC card would work. After messing with the cards and currently playing stuff for awhile, sometimes the SDXC would start working again. I've never had issues accessing the sdxc with a card reader. Then a week or two later this would happen again. Sometimes I'd find my player inexplicably at 0% battery though it shut down correctly with plenty left and the issue would happen. Sometimes I get a white crash screen, it says something to the effect of panic, trying to write to an empty dir or something close to that. Sometimes when the issue is about to happen I'll hear part of a previous song in the middle of the current song, like the buffer wasn't filled properly. I have tried reformatting the card, this helped for quite a while. I have tried separately fully reinstalling rockbox on the player, this didn't help at all. Then the battery issue started happening more often. I noticed that if I shut off, then plugged the player in when the issue happened, it usually would just start working as intended when it turned out. If I disconnected it with low battery it would have this issue almost immediately. If at high battery, it's a crapshoot, could be as little as a minute, could be as long as several hours.

Other things I noticed, when the issue is happening, the symbol for accessing the mem card stays on indefinitely. Even when nothing from the card is playing and the player is playing something from internal just fine, but the SDXC is in. When I charge the player it shows one battery level, but when I remove the charger it usually drops to a far different level. When I add the entire contents of the mem card to current playlist (I just listen to everything on random) sometimes it works very fast, this is a sign that things are ok. Other times like halfway through the speed at which things are being added drops in like half, and that's a sign things are gonna go bad soon. Enqueueing things shuffled breaks the thing almost every time. Shuffle mode breaks the thing almost every time. The trick that's been working for me is having it plugged in and working with nothing in the playlist, shuffle mode off, and the card in. Then adding the main folder recursively not shuffled. This works 99% of the time when plugged in. Then I go to Now Playing and play the first song. I go to the track list and I shuffle the playlist (not shuffle mode, an actual reordering of the list). Then hit play again on whatever track. Then I can remove the player from the charger and have no issues for awhile. Even with resets and skipping alot. But it always comes back. Then I hard shut down the player and plug it in. Usually that solves it and I can keep using it.

This is a really weird issue, I know some people have been having trouble with this sdxc card and this player, but I was unable to find anybody with quite the same issue (forgive me if I should have looked harder). Do any devs have a clue what could be causing such a weird combination of symptoms?

[WithARidiculousClip]

Another thing, when the issue is happening, as in it freezes up. Then I shut it off, take the card out, restart until it auto clears the playlist, play something from internal, then put in the SDXC: I can browse the sdxc just fine. The little symbol stays on, but it doesn't seem to affect it. I can even stop playback and add stuff to the playlist without issues. It's only when I hit play that it freezes again.