Hi,
Since you have tried before with no success."
"Tried everything to reformat it it keeps coming back as 32gig.
Copied the firmware but it is spread over 2 hidden partitions"
I have found this fix from other site shared by Random667.
Why not give this a try?
Hope this help.
"Random667 said
November 14, 2009 at 5:38 am
I just tried this on an newer version touchscreen mp4 player.
It was supposed to be 32gb but was only 3.8gb.
I opened the Check Flash 1.10 program,
selected the drive,
selected as a “physical device”,
Selected “low level initialization”
Hit Start,
Hit new,
Selected Fat32,
Moved the slider to around 4gb,
Hit OK,
Hit OK,
Hit cancel
The device now shows up in windows as 3.81gb "