You should read that thread anyways, on card corruption. Then, since you are buying a new one to replace it, his article on card optimization. Another excellent article.
Talks about problem cards, correct formatting for optimum results.
Then, finally, read his article on backup software. He is a wealth of information. I believe he has no life and just sits in a dark room with Coke and Pizza reviewing and writing.
Thank god he does, its great information we all could use.
-Edgar