There is a maximum of 32KB per cluster with the space demanded for file allocation table. The maximum possible cluster number on a FAT32 volume is 268,435,445.Users can't increase cluster size on a volume using FAT32 file system format so that clusters is less than 65,527. A FAT32 volume must contain at least 65,527 clusters.Clusters can't be larger than 64KB otherwise some application won't be able to calcite disk space correctly.This part explains limitations existing in FAT32 file system with Windows operating system, which can account for the volume too big issue.

FAT32 is flexible and robust file system providing enhancements over previous FAT file system, and yet it has a couple of limitations.

Is there other solution out there that can help me?'

But that didn't work and gave error ‘The volume is too big for FAT32' after it hit 90 percent. All advise to format hard disk with command prompt. I tried on Windows 7 computer, but FAT32 is not available. 'I' tried formatting my 500GB external hard drive to FAT32 so that I can use it on PS3. Though it's recommended to format disk into NTFS, some users still want to format removable disk to FAT32 in order to transfer files from Mac. Most computer users own more than one hard drives or external drives. However, if the hard drive is 1TB or larger, the formatting will give error 'The volume is too big for FAT32'. Windows can format a disk which is larger than 32GB to FAT32 with DOS command prompt. If you format a large partition or USB hard drive to FAT32 file system under Windows, you can only see NTFS or exFAT in the drop list for file system section. Symptom of 'The volume is too big for FAT32' error

Method 2: Format disk with free FAT32 format tool.

Method 1: Format USB / HDD to FAT32 with Command Prompt.

Solutions to fix 'The volume is too big for FAT32'.

Symptom of 'The volume is too big for FAT32' error.

Fat32 formatter