I had the same problem, my exFAT volume was gone, Disk Util said "
invalid sector size: 0" and it was not able to repair the volume.
This worked for me: Open up Terminal and type
Code:
[B]sudo fsck_exfat -d [COLOR=#3E3E3E]disk1s2[/COLOR][/B]
, assuming that
disk1s2 is the volume in question.
After fsck_exfat has finished, it asks you "Main boot region needs to be updated. Update?". Type "Yes" and hit Enter.
After that, go back into Disk Util, now the right name of your volume should appear instead of "
disk1s2". Now, repair the volume, this time it should work. Disk Util will print out the following:
Code:
Checking main boot region.Checking system files.
Volume name is ORIGINAL_NAME.
Checking upper case translation table.
Checking file system hierarchy.
Checking active bitmap.
Rechecking main boot region.
Rechecking alternate boot region.
The volume ORIGINAL_NAME appears to be OK.
I suspect in my case a running application which had opened files on the exFAT volume, which has not been shutdown properly when I rebooted Mac OS X.