The SCCM 2012 Standalone media wizard will not allow you to create USB media with .WIM files that are larger than 4095MB. The wizard will however create .ISO with WIM's larger than 4095MB. The wizard splits the .WIM files into multiple files smaller than 4095MB. Use the information below as a work around to create Bootable USB media with Large WIM files.
1. Create a Standalone media .ISO with the command line below. You must create the ISO via a command line because the SCCM wizard max ISO size is 8.5GB. This will cause you to have multiple ISO's. By using a command line you can specify the max .ISO file size to be larger with the /M switch which will create one large ISO. Replace the following Parameters below with information from your environment /P:"ManagementPoint" /S:"SiteCode" /D:"DistributionPoint" /A:"TaskID"
"C:\Program Files (x86)\Microsoft Configuration Manager\AdminConsole\bin\i386\CreateMedia.exe" /K:full /P:" ManagementPoint.domain.com" /S:" TST" /C:"" /D:" DistributionPoint.Domain.com" /L:"Configuration Manager 2012" /A:"TST00011" /Z:"False" /T:"CD" /M:"44482" /F:"C:\Deployment.iso"
Note: You can monitor the ISO creation by viewing the following log file (use CMTRACE.exe for best results). C:\Program Files (x86)\Microsoft Configuration Manager\AdminConsole\AdminUILog\CreateTsMedia.log
2. Open an Administrator Command prompt and use Diskpart to configure your USB drive. Be sure to enter the correct disk number for your USB drive. (CAUTION THIS WILL ERASE ALL DATA ON THE DRIVE THAT YOU SELECT)
Note: I am setting my Partition to a size of 16GB. This may not be necessary but I am trying this due to problems I have read about with USB drives larger than 16GB.
Select Disk ?
Create Partition Primary size=15175
Select Partition 1
Format FS=FAT32 Quick
3. Mount the ISO file that was created. I use Virtual Clone drive from Slysoft to do this. (My favorite ISO mounting tool, Spyware free, doesn’t require a reboot, and free to use)
"C:\Program Files (x86)\Elaborate Bytes\VirtualCloneDrive\VCDMount.exe" C:\Deployment.iso
4. Use Xcopy to copy all of the files from the mounted ISO to the USB drive. You may need to modify the drive letters for your environment.
xcopy E:\*.* /s /e /f Z:\
5. This is the command line that unmounts the ISO using Virtual Clone Drive.
"C:\Program Files (x86)\Elaborate Bytes\VirtualCloneDrive\VCDMount.exe" /u