>>Start without the card in the unit. When GE asks for it put it in then
I did just that, but it never asked for the card. All I get is a message about there not being enough space on the nuvi to build the map, Express uses the full 7.5Gb available. As you can imagine there is a bare minimum of files on the nuvi. This version(3.3) of Express apparently supports an additional SD card.
Update: Think I might have it. The finish is in sight.
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