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OS Recovery tool error extracting image file usbkey.zip

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I just download a few minutes ago from https://www.dell.com/support/home/ch/fr/chdhs1/drivers/osiso/recoverytool/wt64a the OS Recovery Tool. Put a 32GB USB key into my computer and try to create the recovery USB with that application.

I wasn't able to complete the process as I received the following error

Sorry. An error occurred while extracting image file usbkey.zip. Please check the file and try again.

I've seen I'm not the first one having this issue so there is definitely something wrong with Dell's app. Anyone has an idea or an old version of the tool?

I have already tried all suggestions that I was able to find before posting. Thanks for any advise !

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5 Iridium

Re: OS Recovery tool error extracting image file usbkey.zip

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In the following post it seems like the suggestions work.

https://www.dell.com/community/Productivity-Software/OS-Recover-Tool-ISO-Image-Error/td-p/5167848




-Forum Member since 2016
-I do not work for Dell
-A user helping other users
-If you like an answer please click on thumbs up
-If a reply is a solution to your problem please click on Accept as Solution
Gaming on a home built with MSI B450-A Pro Max with Ryzen 7 2700X
Real work on an Inspiron 15 5575 and Latitude E5430

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5 Iridium

Re: OS Recovery tool error extracting image file usbkey.zip

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Welcome to the Dell Community  @BRabbit27 

Use the Dell OS Recovery Tool to create a USB recovery drive that you can use to reinstall the version of Windows or Linux that came with your PC:

https://www.dell.com/support/home/us/en/19/Drivers/OSISO/recoverytool

First “Create” a new folder on your desktop called "Dell OS"

Then "Extract" the file to that folder.

Then go to that folder and double click on "DellOSRecoveryTool"

It should then produce a desktop shortcut called "DellOSRecoveryTool"

Double click on that desktop shortcut to start the process to create the USB Recovery drive.

Best regards,

U2

HP EliteBook 8770w i7-3630QM 32GB
HP ZBook 17 G2 i5-4310M 16GB
HP Color LaserJet M553dn 40ppm

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5 Iridium

Re: OS Recovery tool error extracting image file usbkey.zip

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In the following post it seems like the suggestions work.

https://www.dell.com/community/Productivity-Software/OS-Recover-Tool-ISO-Image-Error/td-p/5167848




-Forum Member since 2016
-I do not work for Dell
-A user helping other users
-If you like an answer please click on thumbs up
-If a reply is a solution to your problem please click on Accept as Solution
Gaming on a home built with MSI B450-A Pro Max with Ryzen 7 2700X
Real work on an Inspiron 15 5575 and Latitude E5430

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1 Copper

Re: OS Recovery tool error extracting image file usbkey.zip

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Thanks for the reply. That solution dates of 2017 and as you can imagine I tried it without any luck hence why I resposted.

I really appreciate the time you took to write. Nevertheless Dell's customer support said that they cannot help me since my support warranty expired.

So I will look for a solution myself and never, ever will buy again from Dell.

Cheers

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5 Iridium

Re: OS Recovery tool error extracting image file usbkey.zip

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Welcome to the Dell Community  @BRabbit27 

Use the Dell OS Recovery Tool to create a USB recovery drive that you can use to reinstall the version of Windows or Linux that came with your PC:

https://www.dell.com/support/home/us/en/19/Drivers/OSISO/recoverytool

First “Create” a new folder on your desktop called "Dell OS"

Then "Extract" the file to that folder.

Then go to that folder and double click on "DellOSRecoveryTool"

It should then produce a desktop shortcut called "DellOSRecoveryTool"

Double click on that desktop shortcut to start the process to create the USB Recovery drive.

Best regards,

U2

HP EliteBook 8770w i7-3630QM 32GB
HP ZBook 17 G2 i5-4310M 16GB
HP Color LaserJet M553dn 40ppm

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1 Copper

Re: OS Recovery tool error extracting image file usbkey.zip

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Unfortunately, it doesn't work.

I tried on 2 machines.

I ran as administrator.

The USB is 32GB

I checked folder permissions.

Nothing works.

Unfortunately, the rufus altnerative doesn't work either. The tool never creates an ISO (checked with 'everything'). I just creates USBKEY.zip, but doesn't contain nearly enough.

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Re: OS Recovery tool error extracting image file usbkey.zip

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1 Copper

Re: OS Recovery tool error extracting image file usbkey.zip

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Thank you very much, changing the preferred language works. Hope Dell will fix this issue.

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1 Copper

Re: OS Recovery tool error extracting image file usbkey.zip

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Hi, i have same problem. Issue is that OS Recovery tool formats USB flash drive as FAT32, but Windows 10 ISO contains file install.wim 4,48GB. It is too big for FAT32 filesystem. 

I tried format USB flash as exFAT before running OS Recovery, but application reformat back to FAT32 😞

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