Hello,
Yesterday I was attempting to upgrade the firmware of my Passport and faced the exact same problem described in Problems updating Firmware.
The user claims the card “broke” after 2 usages. In my case, it was even worse: I literally had only used the included card once.
I was able to upgrade using a very old and slow (class 4) card I found inside an old phone I had.
Edit: I find that odd, considering it’s an old Adata card vs. an industrial Sandisk.
Just wanted to leave my feedback here about a potential general issue with the cards.
I mean the same situation as the thread I linked: I can copy the files to it, but can’t upgrade the firmware, giving me that error. I also formatted it to see it that could help.
I noticed the card is read very, very slow in the Passport. At first, I thought that was an UI issue (like, “they should’ve added a ‘loading’ animation or something”), but it worked very fast with the older card.
I remember now I was able to install the beta-pub.bin key with the “broken” card, just not the firmware upgrade.