It definitely sounds like a strange one.
I have a Prime Go, Prime 4 and two SC5000Ms and use 128GB and even a 512GB with no issues in any of the devices.
Now these cards weren’t full and I’d not hit 22k tracks on them.
There is one thing to check. When a storage device is in use and either the SD card or USB stick is just pulled out without ejecting it will corrupt. As you’ve not physically removed these it would be safe to overlook the fact there could be a hardware fault that is causing them to be disconnected internally and corrupting the drives.
Now this could be a faulty SD card slot and/or USB port or a cable that’s come loose (I’m not sure if they are on an internal hub or not).
One way to see if they’ve been disconnected is to see if you have any disconnection warnings randomly. It’s just one possible angle.
You could try repairing the latest 4.2 version and then performing a factory reset. If you still Have problems this could be treated as a bug and could be investigated.
Your report was very descriptive and had good steps for a potential reproduction. I spotted that they advertise the offer of beta testing so maybe apply?