I have now made this post Community Wiki, since I have changed it several times. I decided to revert to something close to my original answer, but to highlight different consequences in a different fashion.
For each odd prime $p$, let $e_{p}$ denote the order of $4$ in the multiplicative group of $\mathbb{Z}/p\mathbb{Z},$ and let
$f_{p} = \nu_{p}(4^{e_{p}}-1).$
As usual, when $p$ is a prime and $a\neq 0$ is an integer, we write $p^{r}|| a$ if $p^{r}| a$ and $p^{r+1} \not | a,$ so that we also write $p^{f_{p}} || 4^{e_{p}}-1.$
Notice that $e_{p}$ is always a divisor of $\frac{p-1}{2},$ and that we have $f_{p} > 1 $ if and only if
$p$ is a Wieferich prime.
As the question suggests, we consider a positive integer $k$ which is minimal subject to $4^{k}-1$ being powerful, assuming any such integer exists.
Let $p$ be a prime divisor of $k$, and set $m = \frac{k}{p}.$ Then $4^{m}-1$ is not powerful by the minimal choice of $k$, so there is a prime $q$ such that $q||(4^{m}-1).$ Then $q^{2} | 4^{k}-1$ by hypothesis, so that $q$ divides both $4^{m}-1$ and $\frac{4^{k}-1}{4^{m}-1}$ and hence $q | \frac{k}{m}= p.$ Note also that $q$ is odd, so that $p$ must be odd.
Thus we see that $4^{m}-1 =ph$ where $h$ is a powerful integer coprime to $p$, and since $p$ is odd it follows that
$p^{2} || 4^{k}-1 = 4^{pm}-1 .$ It also follows that
$e_{p}$ is a divisor of $m$ and that $p || 4^{e_{p}}-1,$ so that $p$ is not a Wieferich prime.
On the other hand, if $p$ is a prime divisor of $4^{k}-1$ which does not divide $k$, we know that $p^{2}|4^{k}-1$, so that $e_{p} |k$. If $f_{p} =1$, we must have both $p|4^{e_{p}}-1$ and $p | \frac{4^{k}-1}{4^{e_{p}}-1},$ so that $p | \frac{k}{e_{p}},$ contrary to $p \not | k.$ Thus $f_{p} \geq 2$ and $p$ is a Wieferich prime.
We may now conclude that $4^{k}-1 = k^{2}A,$ where $A$ is the product (over all Wieferich primes $p$ such that $e_{p} | k$) of $p^{f_{p}}.$
Now suppose that $k$ has $n$ different prime factors.
Then these $n$ prime factors are exactly the the non-Wieferich primes which divide $4^{k}-1,$ and all divide $4^{k}-1$ to the second power only.
We claim that at least $2^{n+1}-n-2$ different Wieferich primes divide $4^{k}-1$ (at least to the second power, of course).
Note that a prime $p$ is a divisor of $4^{k}-1$ if and only if $p$ is a primitive prime divisor of $4^{d}-1$ for some divisor $d$ of $k$.
For each divisor $d$ of $k$ (other than $1$ and $3$), there are at least two primitive prime divisors of $4^{d}-1$- one being a primitive prime divisor of $2^{d}-1$ and another being a primitive prime divisor of $2^{2d}-1$.
For different such divisors $d$ and $d^{\prime},$ we see that the respective pairs of associated primes are disjoint, because $4$ has multiplicative order $d$ in $\mathbb{Z}/p\mathbb{Z}$ for either prime $p$ in the first pair and likewise order $d^{\prime}$ for each prime in the second pair.
Now $k$ has $2^{n}$ distinct divisors, so this procedure shows that $4^{k}-1$ has at least $2^{n+1} - 2$ different prime divisors (taking account of $3$ and $7$). Each of these prime factors $p$ divides $4^{k}-1$
to at least the second power.
We have seen that exactly $n$ of these primes are divisors of $k$, and these are exactly the prime divisors of $4^{k}-1$ which are NOT Wieferich primes.
Hence at least $2^{n+1}-n-2$ of the prime divisors of $4^{k}-1$ are Wieferich primes.