I just got a NUVI 3590, and see that it can take up to a 16gb micro card. This may sound like a dumb question but a card that size will have to be formatted in NTFS, right? The question is will the NUVI recognize NTFS?
...I believe with fat32 the biggest file size is 4gb...
Correct.
...but you can format to 16gb.
A FAT32 formatted volume can be much larger than 16GB. That said the SDHC standard only allows up to 32GB cards and they (by the standard) are FAT32 formatted. Cards larger than 32GB are supposed to conform to the SDXC standard and are formatted with exFAT. That said they can be reformatted as FAT32.
Of course you can format any card with NTFS if you wish but practically no device (MP3 player, camera, GPS etc) will recognize it if you do.