Smike, thank you for the excellent post on this frustrating topic. I also have the Roku Ultra 4660X model, and I called Roku Technical Support on the phone twice about this question. The first person was clueless, telling me I should use a "4 gee bee" or "6 gee bee" card. When I asked the maximum size that was supported, she claimed 8 GB. She also said that current Roku Ultra models no longer have the micro SD card slot and have 2 GB of internal memory now instead. I happened to have a 32 GB micro SDHC card lying around, and I asked her if micro SDHC is supported. She said no, it has to be micro SD only.
After I got off the phone and did some research online, I learned that the micro SD standard has a maximum size of 2 GB, and larger cards up to 32 GB are always micro SDHC, then other later standards for cards larger than 32 GB. I called back and reached someone who actually had some computer literacy and understood what he was talking about. He asked me for the serial number of my Roku Ultra, and said that for THIS model (the 4660X), it does support micro SDHC cards up to a maximum of 32 GB. This makes sense, because larger cards use a later standard that wouldn't be supported by a device designed to use micro SDHC. Perhaps they can be fooled into using a larger card if you format it as FAT32 on a computer (micro SDHC uses FAT32), but the best bet is simply to avoid larger cards and use a 32 GB micro SDHC card or smaller.
When I tried my 32 GB micro SDHC card in my Roku Ultra, I initially had trouble getting it to work. First it wouldn't stay in the slot, I finally figured out that I had to use a fingernail or screwdriver or something to push the card in deeper than simply flush with the outside of the case, until it clicks, then it stays in and recognizes the card. It offered to format the card, but that failed. The rep suggested to try formatting it on a PC and then try again. He specifically suggested turning OFF the Quick Format, but that takes forever and I'm not convinced there's any need to do that. At any rate, after I hung up the phone, I tried several more ways to format the card on my PC and ultimately concluded that the card was defective since any attempt to write to it timed out and failed, including from DISKPART.
As for the differing claims as to what cards are supported, I think this entirely depends on which specific model Roku device you're using, and you might need to call their technical support to verify. The second rep did tell me that there have been SIX different versions of the Roku Ultra, and that the older models had the micro SD slot but newer models no longer have the slot. The first rep was right about that part, but he said that the newest model now comes with 4 GB internal memory -- the one with 2 GB of internal memory was apparently a previous model.
Roku makes it very difficult to find this information online, but by researching various snapshots on archive.org of Roku's model comparison page over the years, I was able to get a pretty good idea of the models in the series along with rough approximations of when each model was being sold...
There are actually several earlier models before the Roku Ultra which DO have micro SD slots:
Roku 3 (4200 series) (approx. September 2013 - April 2015)
Roku 2 (4210 series) (approx. June 2015 - September 2016)
Roku 3 (4230 series) (approx. June 2015 - September 2016)
Roku 4 4400X (approx. December 2015 - September 2016)
(There appears to be no product link for the 4400X.)
Given that some people seem to believe that 2 GB is the largest size of micro SD card that actually works in a Roku device, my guess would be that all of the models above probably only support the original micro SD standard for cards up to 2 GB. If that's the case, these models might work best with 2 GB micro SD cards, but that's just a guess!
The first four Roku Ultra models DO have micro SD slots:
Roku Ultra (4640 series) (~December 2016 - ~December 2017)
Roku Ultra 4660X (~October 2017 - ~September 2018)
Roku Ultra 4661X (~September 2018 - ~July 2019)
Roku Ultra (4670 series) (~December 2019 - ~April 2020)
There is also one Roku Ultra LT model which has a micro SD slot:
Roku Ultra LT 4662X (~December 2019 - ~September 2021)
I didn't use the product links for the 4660X, 4661X and 4662X because they're all lumped together:
Roku Ultra (4660, 4661, 4662 series)
The second rep I talked to told me definitively that my 4660X model supports micro SDHC cards up to 32 GB, and Smike's experience seems to confirm that information as well. It's reasonable to assume that all of the models introduced after the 4660X would also support at least 32 GB as well. It's possible that micro SDXC support up to 2 TB could have been added later, but I think that's a long shot. (It seems that 32 GB is plenty of space for this, so why bother?) Still, if it did happen, the 4670X seems like the most likely model to support cards over 32 GB if any do.
As for the original Roku Ultra 4640X, it could go either way. Perhaps it only supported micro SD cards up to 2 GB. On the other hand, the branding change to the "Ultra" name seems like the obvious time to add the micro SDHC support for cards up to 32 GB since that would make the features more "ultra" than the earlier models. (Or maybe my guess about the older models is wrong and they've always supported micro SDHC?) My best guess would be 2 GB for the old Roku models and 32 GB for all the Roku Ultra models and the Roku Ultra LT 4662X, but the only way to be sure would be to test them or find out from Roku.
As for the newest models, the last two Roku Ultra models and the current Roku LT model do NOT have micro SD slots:
Roku Ultra (4800 series) (~November 2020 - ~December 2021)
Roku Ultra 4802X (~July 2022 - March 2023+)
Roku Ultra LT 4801X (~October 2021 - March 2023+)
(There appear to be no product links for the 4801X or 4802X either.)
Presumably the 4800X would be the model with 2 GB internal flash memory and the 4802X would be the newer model with 4 GB internal flash memory, according to what the second rep told me. The 4801X is probably either 2 GB or 4 GB also. (I'm guessing 4 GB but it could go either way.)
I hope this additional information proves useful to someone... I've wasted way too much time on this!