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The card release assembly is located on the back of the rear main circuit board. This is not a repair I would recommend to someone who is not used to dealing with static sensitive circuits and does not have an anti-static setup for repair
You have to remove the back, front, bottom and top covers, then remove the tripod plate on the bottom. This allows you access to the bottom circuit and the marked place to discharge the flash circuit (if the flash circuit is charged, which is is if you leave it on the green rectangle like most people, then you have 300 volts in that part of the circuit and if you do not discharge the flash circuit and you short it out then you can send 300 volts into a 6 volt circuit and short out your camera and turn it into a paperweight). Then you have to remove the main (rear) circuit board to get to this part [CG2-2819-000 PCB Ass\'y, SD] which has to be replaced (the SD card holder is part of this small circuit board). The usual cause of SD card release failures is that a small plastic pin the moves in an inverted V shaped slot breaks off. There is no way to fix this economically. Make sure you use an anti-static mat and ground strap.
If you think I am being overly cautious about discharging the flash - one of the two ground screws that hold the bottom board on in the 7D (similar to 60D) coming out and shorting part of the bottom circuit is the usual cause of the 7D ERR 40 your read about all over the internet.
There might be quite a lot of reasons that may cause this kind of format error problem saying memory card not formatted. Check out this article fix memory card not formatted error and learn how to fix it step by step. Best regards.
I am looking for a mother board for this unit. The USB connect, delaminated from the board and I will be willing to purchase a replacement from a unit with a broken screen or other defect. You may contact me at firstname.lastname@example.org Thanks
Since you mention that it seems to feel different when pressing the on/off button, I can ask if you feel it "click" when you press it? If not, chances are the actual button mounted on the PC Board has broken off of the board. These buttons are mounted using "suface mount technology" which is less durable than through-hole... what that means is that if the button was pressed rather hard even once, it will come off the board and need to be re-soldered on. Other related possibilities are that the plastic "nib" on the end of the button (found inside the unit) has broken off and a new button is required. Don't scrap out the unit, if you or someone you know has good soldering skills, might be worth trying.
The way the TomTom One works (unfortunately) is that it reads either from the SD slot of from internal memory, but not both. So you can't have the SD act as supplemental memory. I had the same problem and was pretty peeved about it. You would have to spring for a more expensive model to get this feature :S