How to Replace Drilled Out Lock Core in Thule Roof Mounted Cargo Box

Updated 04/07/2020 | Published 09/23/2019

Question:

Hi There, My wife and daughters went camping last weekend and broke the key off in our Thule roof box. Of course it was full of the gear they needed to camp, so I had to drill into the core to open the box. Whats remaining of the core is still there, can I just pop it out and replace it with one keyed to second unbrokent key? Any tricks I need to know to remove it?? Thanks

asked by: Blair N

Expert Reply:

So I'm guessing you got enough of the lock core drilled out to unlock it, is that correct? If so, you might be able to use the change key like # 853-1251 to remove the core and replace it with a lock (and key) keyed to the remaining lock if it's not too munched up.

If what remains of the lock is too chewed up, I'd recommend continuing to drill out the core, going up in drill bit diameter one size at a time. The idea is to remove as much as the lock core as possible WITHOUT chewing up the cylinder than holds the lock core. Eventually, with some careful drilling and not too much colorful language (I hope), you'll get to the point where you can remove the remainder of the core with a small screwdriver and some needle nose pliers.

To order a replacement lock, use the part number # THLOCKNXXX and replace the X's with the numbers stamped on the lock next to the key slot. You'll also need to order the replacement key, which would be # THKEYNXXX, once again, substitute the x's for the desired key number. You'll also need the change key I mentioned earlier to install the replacement lock core. If you take a look at the video I've linked for you, you can see how the change key works.

If this happens again, we've had pretty good luck using a dental pick to work the broken piece of the key out far enough that it can be grasped with some pliers.

expert reply by: Mike L

Kevin

4/5/2020

Hello, my lock wont unlock with the key, the removal key slightly pulls it out but not the whole way. How can I get it out if it wont unlock?

Chris R.

4/7/2020

The Universal Change Key can only remove the cylinder if it's already unlocked. If you weren't able to do this (and don't still have the right/original key) then your only options are to either drill out the core like Mike described above or maybe see if a local locksmith might be able to help.