Issues creating a 32GB Windows 7 USB stick

I'm seeing if anyone else has had success installing Windows 7 from a 32GB USB stick. I have tried the Windows 7 USB tool from MS, and I also tried creating a multiboot with YUMI. Both have the same problem: The tool says it created the USB installer successfully. I boot from it. The installer runs, and it gets up to the drive/partition selection. At this point, it absolutely will not install, and instead gives me "Setup was unable to create a new system partition or locate an existing system partition." With any 16GB USB stick I try, it works. I make a 32GB USB stick with the exact same ISO, I get the error.

If you have a known working (ie. installed Windows 7 with it) USB stick that's 32GB or higher, please let me know the make and model of the stick. Thx!

 

I have the feeling this might require a modified .cfg type of file. Does the ISO you're trying to load onto the USB drive contain Service Pack 1 and any/all current/relevant updates?

 

I have tried a variety of images, all official from MS, and all SP1. It's also on a variety of machines, from an Intel mobo desktop to Lenovo laptops to Dell laptops, various models.

 

It could be that you need updated chipset drivers. I've also read that 32-bit versions of Windows 7 encounter problems with 32GB+ pen drives.

Does the drive show up in Disk Management correctly? and have you tried different 32GB sticks?

 

Let me give you the exact, literal, step by step.

Ingredients:

1. Laptop or desktop of indeterminate origin. I can produce this problem on a Lenovo T500, T510, T520, T530, W510, or a Dell Precision 6500, or my Intel motherboard desktop. I repeat - it does the exact same thing on *all* of these. Not some of them. ALL of them.

1. Windows 7 64-bit SP1 ISO - I have tried Pro, Home Premium, Ultimate. These are directly downloaded from Microsoft, via a Volume license agreement. Here's your ISO, here's your key, you have 13 licenses left or whatever.

1. 16GB USB flash stick. Patriot. Kingston. Generic. Second Gen. Third Gen. First Gen. Doesn't matter.

1. 32GB USB flash stick. Patriot. Kingston. Generic. Second Gen. Third Gen. First Gen. Doesn't matter.

1. Windows 7 USB tool from Microsoft. Or YUMI.

I DO NOT MODIFY THE ISO OR THE FINISHED USB STICK

16GB USB
----------------
I create a Windows 7 SP1 bootable installable USB stick with either the Windows 7 USB tool or YUMI.
I boot off said USB stick. Boots with no issues.
Next Next Next > Upgrade> wipe out hard disk > Next > Windows 7 installs perfectly


PRECISE same system. EXACT. No change. None. Not a different hard drive. Not different RAM. Not different ISO (note: as I said, I didn't alter the ISO from Microsoft). Exactly, byte for byte, the same software. Exactly, silicon for silicon, the same laptop or desktop.

32GB USB
-----------------
I create a Windows 7 SP1 bootable installable USB stick with either the Windows 7 USB tool or YUMI
again, same ISO as in the 16GB step, which is an ISO I have not modified. I have not modified it
I boot off said USB stick. Boots with no issues.
Next Next Next > Upgrade > wipe out hard disk > Next > Setup was unable to create a new system partition or locate an existing system partition.

This is the problem I have. I will reiterate I do not change anything.

 

Lol yes, I'm aware of everything you reiterated (but thank you for taking the time to be as detailed as possible). I was just wondering if there was a known firmware issue with the 32GB stick, but it looks like you've tried several manufacturers' pen drives to no avail. So!...

I'm stumped. I've asked around and poked around and utilized my Google Fu, and I can't find any discussions or FAQs or anything that's related.

My recommendation is to contact Microsoft and see if they're familiar with this happening if nobody on NBR can point you in the right direction.