GPSMAP 66i SD Card issues

I was trying to load the 24k maps from Garmin Express to a 32gb card.  The card previously had the same map file that I used for my 66st.   Garmin switched the file on my account to my 66i so I could re download and use on my new device.  Prior to download I reformatted the card on a Mac computer to FAT format.  I downloaded the map file but the 66i would not read it.  Base camp on the computer saw it, but the 66i never did.  I reformatted the card several times and re download, but it never took.   I then took a brand new never used 32g card and tried again, this time it worked.   My concern is, could this be hardware or software? I’m within a return window so torn on what to do.  Would hate to get stuck with the next map purchase not being able to download.   Also FWIW during the 4 or 5 attempts to get the map loaded, the device drained nearly 30% battery.   No way would it get near 35 hours based on what I saw just loading a map.   Anyone else have SD card issues?