XuZhang, thanks for replying. I tried your example code with a new 64GB microSD, and I got an error:
SEGGER J-Link GDB Server V7.96q - Terminal output channel
FATFS example to demonstrate how to use FATFS with SD card.
Please insert a card into board.
Card inserted.
Make file system......The time may be long if the card capacity is big.
Make file system failed.
Out of curiosity, I tried a different FRDMK66 board - I have two - and with the newer FRDMK66 board, the example code worked like yours with a 64GB microSD. So it's partly a hardware issue. I can live with that, since the older FRDMK66 will be used in a harsh environment, and a 2GB SD card should work well enough.
I don't consider this resolved - it should work the same on both boards, I'd think - but you can close the issue. Thanks!