Thing is: if that was a checksum problem, camera wouldn't work (either black screen or a crash) as it would still load the (broken) binary.
With that problematic card (after preparation, and with ML files on it) - do you see any activity from card access LED immediately after turning the camera on?
The behaviour I saw with the current problematic card is how it was with the other card too. for sake of clarity in discussing lets call the previous card 64gb (which worked after renaming autoexec) and the second card as 32gb (because that is the capacity of the cards).
So 64gb card-
Format card, Camera in M mode, remove card, extract ML to the card, copy BOOT FIR, EOScard updates card to bootable, insert card into camera, run firmware update, ML Rescue screen asking to remove battery, battery removed, card removed, on computer - update autoexec file name on the card, insert card back to camera, camera does not appear to start, press SET and start, camera starts, rename autoexec on computer, reinsert card, start camera, ML loads on pressing trash can button.
32gb card -
Format card, camera in M mode, remove card, extract ML to the card, copy BOOT FIR, EOS card updates card to bootable, insert card into camera, run firmware updaate, ML Rescue screen asking to remove battery, battery removed and reinserted, camera started, ML did not load.
I removed 32gb card, inserted 64gb card, used camera on the weekend.
After Kitor's message just now, inserted 32gb card, LED shows long blink and one bleep after closing compartment. Started camera, LED showed one long blink and then rapid blinks more than 4 (couldnt count, probably 5 or 6). however this time, pressing trash can button loads ML.
wonder if Camera has a cache or something that is taking time to clear.
Trying the whole process again with 32gb card.