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Help Micro SD card Formatting Problems on HTC Hero

I have a Sprint HTC Hero and an SanDisk 8gb series 4 card. I upgraded to a 16gb and want to continue to use this card. I transferred all my data over to the new card using the phone as a disk drive to my computer and put the 16gb card into a usb card reader. All of the data transferred fine. Now I try to access my 8gb card on my computer and it wants me to format it. I try and then I get an error message basically stating it was not able to format it. The file system is now RAW and reads 0 bytes. I put the card back in my phone and it will read that it has 7.39 gb free space I then format it again on the phone and unmount it. I put it back in my computer and same thing happens. Just for the heck of it I try to transfer some pics over to the card from my computer and it was successful. I put the card back in the phone and it will read the pics. I can see them on the phone but I cannot format it to a Fat 32 file system on my computer. What the heck is going on here? What can I do to get this card to work right. I would like to use it on my Nook Color.
 
Have you tried just throwing it in the Nook and formating it that way? I know that's what I always do with a new SD card. That way I know it is formatted properly for the device I am trying to use it with.
 
Not yet, I'm actually wanting to use the card to load android 2.2 ROM on there to boot and make it into a tablet pc. Obviously the card is working but I know nothing about the file structure of an SD card. I'm assuming it has some sort of MBR and maybe that is what is corrupted but not sure why it wont format.
 
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