Hi Guys, thought i would share this information with you all.

Problem:
If you set memory password on your phone then try to open the card with a card reader on a pc and you will find the PC "locks up" until you remove the card.  Then if you try put the card back into your phone you will get a Memory Card Corrupt message.

REMEMBER: Choose no when the phone asks you to format the card, especially if you have valuable data on it.

How to recover:

1. Download and install r-studio (powerful and cost-effective undelete and data recovery software)

About R-Studio 4.0:
R-Studio is a family of powerful and cost-effective undelete and data recovery software. Empowered by the new unique data recovery technologies, it is the most comprehensive data recovery solution for recovery files from FAT12/16/32, NTFS, NTFS5 (created or updated by Windows 2000/XP/2003/Vista), HFS/HFS+ (Macintosh), Little and Big Endian variants of UFS1/UFS2 (FreeBSD/OpenBSD/NetBSD/Solaris) and Ext2FS/Ext3FS (Linux) partitions. It functions on local and network disks, even if such partitions are formatted, damaged or deleted. Flexible parameter settings give you absolute control over data recovery.
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2. Return the card to the PC and run R-Studio.
3. After card has been recovered return the card to the phone and you should be back working fine.

I suspect the issue is related to how the Symbian OS creates the password on the card, best advise is to either not set a password or remove it prior to putting the card into your PC.

And of course you should always have a backup of your sensitive data anyway!

Hope this will helps someone.