if I put the old card in, it backups fine.
From the topic about the recovery..
Always check recovery.log before posting your issues! You can do this by doing :
"cat /tmp/recovery.log" OR "cat /cache/recovery/log" right after you had the issue. Use the "move log to sd" option in the "others" menu right after you had the issue. This will move the log to /sdcard/recovery.log so you can easily open it with a text editor.
Don't really know what this means but it looks like where the problem is...
Install from internal_sdcard...
Finding update package...
I:Update location: INTERNALSD:Business_ICS4.0.3_Sense3.6-v2.2.zip
Opening update package...
I:Update file path: /internal_sdcard/Business_ICS4.0.3_Sense3.6-v2.2.zip
E:Can't open /internal_sdcard/Business_ICS4.0.3_Sense3.6-v2.2.zip
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