You are only able to partition your flash from within exec mode, with a maximum of 2 partitions, and each partition is configurable in size.
For example you can format 16Mb with 2 partitions each with 8Mb in each, this is achieved as follows:-
router(config)#partition flash: 2 8 8
This command creates 2 partions, the first partion is set to 8Mb and so is the second.The same applies if you have an external PCMCIA, partition slot0: 2 4 4.
Unfortunately, until you're able to boot from within rommon a valid image file your options are limited.
You shouldn't have any problems using xmodem, the fact that you have tried the flash in another router and have the same problems would suggest faulty module.
There are two flash simm banks within the 3660, have you tried copying a valid image file from one flash memory to another. I have done this on a 3640, where both the system and boot image had been deleted. Boot from one module and then try copying the image across.
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