Create task sequence media larger than 32GB

I recently ran into a problem trying to create stand-alone media onto a USB key using ConfigMgr 2012 SP1. The task sequence contained driver packages, applications, operating system images and other content that totalled more than 32GB. Due to a combination of the ConfigMgr console Operating System, ConfigMgr itself, the USB disk formatting method/type and the USB stick size, doing this without prior tweaking is not possible. Windows 7/8,Server 2008/08R2/2012 isn’t able to cope with a partition greater than 32GB in conjunction with the ConfigMgr bootable media creation process.

This is what I needed to do to create a 64GB bootable USB stick.

  • Make sure the USB drive in question is removable media and not detected as a portable hard drive, or it won’t be seen by the console (USB stick, USB key required, not USB hard drive).
  • Use a Windows 7, 8, Server 2008/R2 or 2012 machine to format the USB stick with NTFS.
  • Find an old Windows XP machine (yes, they do still have a use) and install the ConfigMgr 2012 console on it.

Windows XP is able to work with drives >32GB, but if you try running the task sequence media wizard at this point, it will fail with the following error:

Query for Win32_Volumes failed. 80041010. Failed to determine whether or not <Drive> is the boot or system volume. Failed to create media (0x80041010).

Win32_VolumesFailure

This is because Windows XP does not have the Win32_Volume class that is used to query available drives.

We therefore need to add the class.

  •  Copy the following MOF text into a new file called config.mof and store it locally on the XP machine with the console installed (e.g. C:\config.mof)

#pragma namespace (“\\\\.\\root\\cimv2″)

Class Win32_Volume
{
[KEY]
String Name;
Boolean BootVolume;
Boolean SystemVolume;
};

Instance of Win32_Volume
{
Name=”E:\\”;
BootVolume=FALSE;
SystemVolume=FALSE;
};

  • Replace the red text above (E:) with the drive letter of your USB drive and save the mof file – note: keep the double backslashes.
  • It may also be necessary to replace the quotes around the text in red and the text on line 1, as wordpress converts them into incompatible speech-marks.
  • Open command prompt and run the following command:

mofcomp.exe <pathToMOF>\Config.mof

e.g.  mofcomp.exe C:\Config.mof

  • Now run the task sequence media wizard and select Stand-alone media.
  • Select USB flash drive and select your drive.

If the following warning comes up, just ignore it, the process will still work fine:

The USB flash drive is not formatted correctly. Format the USB flash drive from a Windows Vista or later operating system.

FormatWarning

  •  Complete the wizard with your desired options.

The process will take a while to complete but you’ll have a nice USB stick >32GB at the end.
Be sure to monitor CreateTsMedia.log in the console install directory (e.g. .\Program Files\Configuration Manager Console\AdminUILog   or .\Program Files (x86)\Microsoft Configuration Manager\AdminConsole\AdminUILog) for progress.

 

It may be necessary to make the USB drive bootable at the end of the process. To do this, just run the following command in an elevated command shell:

bootsect.exe /nt60 E:\ /force /mbr

  • Replace the red text above (E:) with the drive letter of your USB drive.

Note: If bootsect.exe cannot be found in it’s default location (%WinDir%\System32), you can locate it in the Windows 7/8 source media .\boot folder.

 

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