How to Remove Broken Key From Lock of Thule Roof Cargo Box

Published 02/27/2020

Products Featured in This Question

Replacement Lock Cylinder for Thule Racks and Carriers - N166

(583)

$20.20

Thule One-Key System Lock Cylinders - Qty 2

(786)

$54.95

Question:

I have a Thule cargo carrier that has a lock with n166 on it. I accidentally broke the key off in the lock. There is no way to retrieve it as we have tried everything. How can I replace the locking system, or maybe the lock cylinder, so that i can still use the product. I have seen nothing on how to do this. Do i need the entire lock system or just where the key goes in? Please help!

asked by: Justin

Expert Reply:

I've had good luck in the past using dental pics, working at both ends of the narrow edge of the broken-off key at the same time. Once you get a portion of the key slid out you can use a pair of pliers to grasp and remove the broken off portion. Most hardware stores sell an assortment of dental pics, they're handy to have around.

If that fails, the best course of action is to drill out the lock core, however this must be done very carefully. The best way to accomplish this is to start out with a small bit and work your way up in size, until enough of the lock core has been drilled out so it can be removed. You'll want to be extremely careful not to damage the cylinder the lock sits in, because if the cylinder is damaged, you won't be able to install a new lock core. You might be best served by getting a locksmith to drill the lock core out for you.

Once you get the old core removed, you'd need a replacement like # TH450200.

expert reply by: Mike L