Are you in Phantom or Naza-M mode?
S2 is on the left and S1 on the right. So your left switch was in middle position, and your right switch was in top position?
Did you notice the LEDs on the rear legs flashing?
Harder to measure the cover. It's very flexible. And it appears to be ~0.1-0.2mm larger in dia, but has 6 'ribs' that protrude to give it a slight interference fit.
On a flight today, I reset my home after climbing to 80ft (above the highest tree). I stayed at that height for the entire flight until I lost control. Phantom went RTH mode. It climbed to 150ft, turned toward home, and came back.
Edit: firmware 3.04
32GB is the max size that the Phantom can use.
But your card is not useless. You can resize the card by changing the partition size.
I used Partition Wizard to resize a 64GB down to a 32GB and it works fine in my Phantom.
BTW, I did some speed tests with the various cards I have, and the 4GB...
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