[Desire Q&A, Help & Troubleshooting] castro145:
This is what I did them I got a new card, I had this in another post so just cut and pasted, my solution to moving to a new card. Bering a new member I can't post the link in here, but here is the copy of it here.

My setup, 2GB no class listed MicroSD, HTC Desire, Rooted with MoDaCo r9, with A2SD. All of my apps are on the MicroSD pretty much.

Well the MicroSD came in and I did what I know how to do, I used a cloning program that I use all the time for PCs, figured what the hell it should work.

- I plugged both of the MicoSDs using the SD adapter, then plugged the SD adapter into an SD to USB adapter and plugged them into the PC.

- I used Acronis True Image 2010 Acronis True Image , did an exact clone (called "Disk Clone" in the Acronis software), from my 2GB MicroSD to the 16GB MicroSD. Did NOT adjust any partitions or anything, had 14GB of free unused, unpartitioned space on the new card.

- Then I took the new 16GB MicroSD and plugged it back into my phone, booted, and it worked great, the phone can't even tell that it's a new MicroSD, shows same sizes and everything, as I didn't adjust any partition sizes yet.

- Then I took the MicroSD back out, plugged it back into the PC, then used another product of Acronis, called Disk Director Disk Director and then went in and expanded/resized the FAT partition to the full size, it used the free unused space to do that, and moved the partitions down the line and expands the FAT one in place.

- Plugged the card back into my phone, booted, worked great, got 15 GB plus of space now on the FAT partition. All the apps works, everything works great. It seems a little snappier and faster when loading apps now.

Side notes:

I just happened to have both of these products installed on my PC and use them all the time so that's what I used, but any Disk Cloning program that supports USB will work.

There is plenty of other "cloning" programs out there, like Norton Ghost - not free, some other pais ones. But also bunch free ones as well a list of them here , wiki list of them as well. Some of these programs are LiveCDs, which means you boot your PC of a CD and then you can edit HDs, also the USB Drives, other like Acronis will have a PC program as well a boot disk. With acorns I was able to use it just as a program no booting of a CD.

I personally have used this program called "hdclone" which is free, it has one limitations but it really is not a big deal in this case, it limits the copying to 1 GB per minute, hell for 16GB card thats 16 minutes !!! so not a limitation really. So do a exact clone using HDclone, don't resize the new SD just leave it as is, this worked for me, I think leaves everything exact as possible. Another free cloning program I have used in the past is DriveImage XML , so either of these will work to clone one SD to another. Now to resize, the product I use ALL the time to resize drives is "gparted", this one is a boot CD, so all you gotta do, plug in your SD card using the USB, boot of this small GParted CD, select your drive and then expand the FAT partition. Few extra steps with some free products but it works if you're not able to acquire Acronis.

Hope this helps, let me know if you have any questions or problems. Sorry for the long write up but haven't seen anybody describe doing this plus some people aren't as familiar with cloning HDs as others.