A week ago I started getting intermittent IO errors accessing the SD card on my rooted Evo 4g. I eventually plugged it into my windows machine and tried to format it. It appeared to work, but when I unmounted and remounted the card all the files came back. I tried formatting on my phone with the same result, and had a coworker try with the Mac diskutils suite. All the formats claimed to work, but the files came back when the card was remounted. Finally I ran dd if=/dev/zero of=/dev/block/mmcblk0; it completed, and the same thing happened again.
But here is where it gets crazy. I put a new recovery file on the sd card -- and it added the file without any issue. But now it can't be deleted, just like everything else. So I can write to the SD card, but I can't delete anything.
How can I fix this? Or if I can't, at least why is it happening?