I'm incredibly frustrated atm with both my phone/SD card issue and the fact that Samsung chat agents apparently do not know how to read the information I'm giving them.
I've had my S4 since late June, purchased a 32gb PNY SD card the same day. Everything was fine for weeks. 3 weeks ago I had my first SD card error, reformatted the card and everything was ok for about a week. Woke up a week ago Wednesday to 'SD card damaged' and the phone pretty much unresponsive, so I restarted the phone and hit the shower. When I got back to my phone it was stuck in perpetual boot loop and no matter what I did, it wouldn't stop.
Performed factory reset, and reformatted card. Moved audio/movie back to SD card, redownloaded my apps. Synced other files (contacts) back to phone.
Last night was my son's first ever marching performance with the HS band. Took several videos. On the way home, he wanted to watch them. Gallery froze every time. Videos were inaccessible. When we came home, I hooked up the phone to my computer to transfer the files and delete them after, no go. Immediate I/O message. Sigh. Reseated card in case it had become unmounted. Nope, didn't fix it either. Removed SD card and plugged it directly into microSD slot in my PC. Didn't work either. I'm currently performing the long format suggested by someone else in this thread (sorry, can't remember your name atm), and I hope this will fix it.
While all of this was going on, my phone got piping hot just below the flash and drained a good 40% of the camera in less than one hour... I have noticed this issue in the past, and it's usually an indicator for me that my card and phone are about to go to war with one another. Phone gets hot around SD card/sim slot, battery drainage? Yup, better watch out because it's about to get ugly.
So far Samsung Chat is no help. I had to repeat myself several times to get info across and the agent would still ask for the same info again. Rather frustrating. I'm also told that is must be an SD card issue.
I'd love to post the chat log here, but it's already as long as War & Peace and we're not done chatting yet. Sigh.
Eta: The agent insists it's definitely a card issue and has nothing to do with the phone. Obvious stall tactic, no manufacturer wants to come out and admit that there is something wrong with their product. I would suggest that everyone who has issues with this to forgo using Samsung Chat and go directly to Samsung technical support. Their phone number can be found on their website.