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Fix usb error on drive with no existing partitions (#4151)

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Chris Titus
2026-03-04 11:44:10 -06:00
committed by GitHub
parent 9769cafa7d
commit 7f46e8d60d
1 changed files with 35 additions and 8 deletions
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43
functions/private/Invoke-WinUtilISOUSB.ps1
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@@ -103,13 +103,24 @@ function Invoke-WinUtilISOWriteUSB {
try {
SetProgress "Formatting USB drive..." 10
# Phase 1: Clean disk via diskpart
# Phase 1: Clean disk via diskpart (retry once if the drive is not yet ready)
$dpFile1 = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
"select disk $diskNum`nclean`nexit" | Set-Content -Path $dpFile1 -Encoding ASCII
Log "Running diskpart clean on Disk $diskNum..."
diskpart /s $dpFile1 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log " diskpart: $_" }
$dpCleanOut = diskpart /s $dpFile1 2>&1
$dpCleanOut | Where-Object { $_ -match '\S' } | ForEach-Object { Log " diskpart: $_" }
Remove-Item $dpFile1 -Force -ErrorAction SilentlyContinue
if (($dpCleanOut -join ' ') -match 'device is not ready') {
Log "Disk $diskNum was not ready; waiting 5 seconds and retrying clean..."
Start-Sleep -Seconds 5
Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
$dpFile1b = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
"select disk $diskNum`nclean`nexit" | Set-Content -Path $dpFile1b -Encoding ASCII
diskpart /s $dpFile1b 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log " diskpart: $_" }
Remove-Item $dpFile1b -Force -ErrorAction SilentlyContinue
}
# Phase 2: Initialize as GPT
Start-Sleep -Seconds 2
Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
@@ -122,7 +133,8 @@ function Invoke-WinUtilISOWriteUSB {
Log "Disk $diskNum converted to GPT (was $($diskObj.PartitionStyle))."
}
# Phase 3: Create FAT32 partition via diskpart
# Phase 3: Create FAT32 partition via diskpart, then format with Format-Volume
# (diskpart's 'format' command can fail with "no volume selected" on fresh/never-formatted drives)
$volLabel = "W11-" + (Get-Date).ToString('yyMMdd')
$dpFile2 = Join-Path $env:TEMP "winutil_diskpart2_$(Get-Random).txt"
$maxFat32PartitionMB = 32768
@@ -136,29 +148,38 @@ function Invoke-WinUtilISOWriteUSB {
@(
"select disk $diskNum"
$createPartitionCommand
"select partition 1"
"format quick fs=fat32 label=`"$volLabel`""
"exit"
) | Set-Content -Path $dpFile2 -Encoding ASCII
Log "Creating partitions on Disk $diskNum..."
diskpart /s $dpFile2 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log " diskpart: $_" }
Remove-Item $dpFile2 -Force -ErrorAction SilentlyContinue
SetProgress "Assigning drive letters..." 30
SetProgress "Formatting USB partition..." 25
Start-Sleep -Seconds 3
Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
$partitions = Get-Partition -DiskNumber $diskNum -ErrorAction Stop
Log "Partitions on Disk $diskNum after format: $($partitions.Count)"
Log "Partitions on Disk $diskNum after creation: $($partitions.Count)"
foreach ($p in $partitions) {
Log " Partition $($p.PartitionNumber) Type=$($p.Type) Letter=$($p.DriveLetter) Size=$([math]::Round($p.Size/1MB))MB"
}
$winpePart = $partitions | Where-Object { $_.Type -eq "Basic" } | Select-Object -Last 1
if (-not $winpePart) {
throw "Could not find the WINPE (Basic) partition on Disk $diskNum after format."
throw "Could not find the Basic partition on Disk $diskNum after creation."
}
# Format using Format-Volume (reliable on fresh drives; diskpart format fails
# with 'no volume selected' when the partition has never been formatted before)
Log "Formatting Partition $($winpePart.PartitionNumber) as FAT32 (label: $volLabel)..."
Get-Partition -DiskNumber $diskNum -PartitionNumber $winpePart.PartitionNumber |
Format-Volume -FileSystem FAT32 -NewFileSystemLabel $volLabel -Force -Confirm:$false | Out-Null
Log "Partition $($winpePart.PartitionNumber) formatted as FAT32."
SetProgress "Assigning drive letters..." 30
Start-Sleep -Seconds 2
Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
try { Remove-PartitionAccessPath -DiskNumber $diskNum -PartitionNumber $winpePart.PartitionNumber -AccessPath "$($winpePart.DriveLetter):" -ErrorAction SilentlyContinue } catch {}
$usbLetter = Get-FreeDriveLetter
if (-not $usbLetter) { throw "No free drive letters (D-Z) available to assign to the USB data partition." }
@@ -167,6 +188,12 @@ function Invoke-WinUtilISOWriteUSB {
Start-Sleep -Seconds 2
$usbDrive = "${usbLetter}:"
$retries = 0
while (-not (Test-Path $usbDrive) -and $retries -lt 6) {
$retries++
Log "Waiting for $usbDrive to become accessible (attempt $retries/6)..."
Start-Sleep -Seconds 2
}
if (-not (Test-Path $usbDrive)) { throw "Drive $usbDrive is not accessible after letter assignment." }
Log "USB data partition: $usbDrive"