Need Help With RoadMate 6000T firmware update

Have RoadMate 6000T with 1.15 firmware. I download the 1.16 and try to
update the firmware, the wizard starts and I turn on the RoadMate, the
wizard sees the gps and it starts the update by deleting the SD card,
after about 15 minitues the wizard turns off and thats all that will
happen. I have a SanDisk 2GB, the gps sees the card. I have tried this
on two computers, 1 with 2000 Pro and with XP Home. I tried unpluging
everything but the mouse and the gps on both computers. I tried using
a Crucial SD 2GB card. Magellans outsource support had me mail the
unit toThales Repair in Fort Worth, Tx. Got it back, they said it was
fixed but it still had the 1.15 firmware in it. Called support and
they said to go ahead and try to upgrade the firmware now. The same
thing is still happening. When the wizard starts the delete mode and
after 2min. the blue progress line goes all the way to the right. It
just sits there for 15min. and then the upgrade wizard disapears. If
anyone can tell me how to solve this problem I would be greatful.
Thanks.

Warren