I don't know what it means to format an SD card as "internal" or "external"; that distinction doesn't make sense to me. But what it sound like to me is that your NAND (internal storage) is burnt out. All flash memory degrades over time (faster the more you write to it) and eventually just becomes completely useless. (To me a little more specific, you usually can read at least some of it, but cannot successfully write to it or reformat it.)

So the deal is, either you'll have to figure out a way to use just the microSD card, or you'll have to replace the phone (since replacing just the NAND is typically not realistic). Since this is apparently a phone that supports Replicant, I would suggest trying really hard to do the former.

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