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How To Replace the Lock Core and Shield On a Thule Force XL Cargo Box

Question:

I have all the parts for this yet not sure the sequence for the shield?

1

Helpful Expert Reply:

I don't have a whole lot of information for you but I spoke with Thule and they informed me that the lock core will need to come out first (with change key part # 853-1251) and then the lock shield part # 05771 can be removed. The lock shield should just fall out as the lock core holds this in place but you may need to twist this one way or another. The new lock shield can then be set into place and secured with the lock core.

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helpful expert reply by:
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Conner L

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Follow up Questions

James D.

It looks like this question was answered for the Thule Force XL. I have a new Thule Force XT - XXL and am trying to change the lock cores to match the lock cores in my other Thule products. The Force XT box came with lock cores already installed not the plastic dummy cores. I insert the key to the current lock cores 45 degrees clockwise and remove that key. I am able to insert the Universal Master Key D1251 into the old lock core. What do I do next? The old lock core doesnt want to come out along with the Master Key i.e., the Master Key comes out without the lock core and the plastic housing for the lock core likewise doesnt want to come out. Im stuck. What next?

Etrailer Expert
Reply from Chris R.

Take a look at the video I linked below that shows the a Thule lock core being changed. The process is the same for all Thule products. As long as the existing core is unlocked, the Universal Key will work to remove it. It might just take some wiggling once it's inserted for it to really catch. I wish I had some more specific tips but if it's an older unit it may just take some trial and error due to debris or corrosion that might be built up inside.

Reply from Austin B.

@JamesD I'm having the same issue as you. No matter how much I wiggle the key, I cannot get the cylinders to come loose. Did you ever figure this out?

Reply from Jamesd

@AustinB This is the reply I got from Thule: "The box will need to be closed in the unlocked position. "They slowly turn the key while pulling and it should come out while the lock is unlocked. "Then use the change key to pull out the lock and then put the new one in." So picture 1 on page 11 of the manual is misleading. Don't start with the key vertically and turn clockwise because vertical is the locked position. Instead start with the key already turned clockwise to the unlocked position and then slowly turn COUNTER-clockwise. (I'm still stuck as neither approach worked for me. Picture 4 looks like the plastic housing around the lock core detaches from the roof box, but it didn't for me and I was afraid to use additional pressure to try to get it to detach.) Good luck! Let me know if you have any success! (And especially whether the plastic housing detaches or not!)

Reply from Joea

@Jamesd were you able to get yours out? I'm having the same issue with mine. Neither the key shield nor the key core are showing any interest in coming out. I've even tried to get behind the key shield with a putty knife, to no avail.

Reply from James D.

@Joea Yes I was able to solve this. The grey housing extends slightly too far out from the lock core so that the key/master key cannot be sufficiently inserted into the core to do what it is supposed to do. I solved this by filing away 1 or 2 mm of the grey plastic housing that was blocking the key/master key from being completely inserted and then everything worked as expected.

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