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Try using either the "Panasonic SD Formatter" or this. Check also to see if your card works and that its not fake using "h2testw".

Depends on where the SDCard is located.

If it's like my eBook reader, where there is an internal microSD slot instead of an actual eMMC chip, then you're kind of screwed, unless you can acquire a backup.

Also wtf, why would it force you to reboot if there is a problem with the SDCard???

Not sure how Android actually handles this, as I have luckily never encountered it, but it might also be that it's not actually off, but it hard locked up trying to flush disk cache to the SDCard. If there isn't a reset button on the device, then there is *usually* a combination of buttons you can hold for 30-60seconds (I know, painful), and that hard-reboots the device.

If you're really unlucky like me once with one of my phones, then not even the reset button will work, and you'll have to get a hairdryier, and painfully un-adhere the back (or the front in modern phones!), and unplug the battery that way... assuming it's not soldered-in

I've had no problems on getting a 128GB microSD card to work with my Android phone. So it must be either the card itself that is the problem or a faulty player.

"you'll have to get a hairdryier, […] and unplug the battery that way..."
Having non removable batteries is already bad enough. At least include a f…ing (Reset) button! Maybe only accessible with a needle to prevent accidental resets.

"internal microSD slot instead of an actual eMMC chip"
That sounds interesting and like something that is easy to backup with dd. But the (missing) reliability of SDs…