Troubleshooting New Thule Key that Won't Turn Lock on Cargo Box

Question

Question:

I went to open my Thule box after hanging up for a couple years and my locks won’t open. Not sure what to do. I did order a replacement key, which I wanted anyway, but I don’t think it’s a key issue.

asked by: Derek P

0

Expert Reply:

Does the key turn at all? Or does it turn but not release the lock mechanism? It is not unusual to need to lightly tap the key all the way into place in the lock core the very first time you use it so that it seats fully. You can use a rubber mallet or small hammer to gently coax the key into its fully-inserted position. This usually does the trick.

expert reply by: Jameson C

0

Dcor

6/7/2024

I am having the same issue. I purchased a replacement key from you. Came in quicker than expected, too! Went to put the key in, perfect. Turned the lock, perfect. Box still won't open. The silver part of the lock sticks out almost an inch. IS it a Button?? are the insides of the locking mechanism not turning? I cannot figure it out.

Jameson C.

6/10/2024

@Dcor Which specific Thule box do you have?

Tribeee

6/11/2025

Our key turns but the trigger doesn’t release the lock

Jameson C.

6/11/2025

@Tribeee Is this a cargo box or a bike rack locking knob?

Tribeee

6/11/2025

@JamesonC It’s a Velo Compact 924-926 Grey release trigger is floppy - key turns but doesn’t release.

Jameson C.

6/11/2025

@Tribeee I wish we carried that brand but since we don't we can't really help with replacement parts for it.

Sam

6/3/2026

If the key is all the way in but the lock still won’t turn. It only turns part way but doesn’t turn enough to now release the key or lock to box

Andrew N.

6/3/2026

@Sam I'd try spraying some lubricant to see if it's just seizing up and needs freed up, then lightly tap the key in there and try to turn. If no luck then maybe the cylinder is defective and needing replaced unfortunately.

Sam

6/4/2026

@AndrewN and any way of changing the barrel if the key won’t come out of it?

Dianne

6/13/2026

@AndrewN the problem here is that the lock works but I cannot lift the lid. Before storing it on the overhead garage lift, I added some WD40 to the locks and the inside lift arms. Still had the problem then, and now using it the first time since last fall. I have these trail sticks to lift the lid, that doesn’t work UGH-! Lol

Answer 1

With new Thule keys sometimes you have to run the key in and out a few times and wiggle it around a bit to get them to turn correctly. The problem is there is sometimes a tiny bit of extra metal on the keys that needs to be worn off by wiggling the…

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Answer 2

Based on the 2820 tumbler and key number matching up (along with the fact that you were able to lock it) you certainly have the correct key for your carrier. If you're not able to insert the key and turn it all the way to unlock the cylinder you…

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Answer 3

To drill out any lock core you want to start off with a small drill bit (tungsten carbide-tipped or cobalt drill bits work best) and then work your way up in drill bit size until the lock core is released. We don't have any videos of this but…

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Answer 4

I spoke with my contact at Thule, and she did have a few suggestions for you to try. She said some people have had success retrieving broken keys using a paperclip. Try wiggling the key out using the paperclip along the ridged side of the key. I have…

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Answer 5

If you've already tried using the silicon spray and there is still no luck, then your best bet is to have the lock cores replaced, unfortunately. What you're going to need to is either call a locksmith and have them remove the key or you can…

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Answer 6

Hey John, thanks for reaching out. Yes we do have a mounting hardware kit for the Thule Excursion cargo box. For that you will need the following: - Replacement QM3 - Quick Mount Hardware - for Adventurer Cargo Box #TH04997

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Answer 7

It's not super common but sometimes lock cylinders can get corroded and not want to turn/unlock. What Thule has told us in the past is to direct some spray lube like WD40 into the key hole and then insert and remove the key several times to help…

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Answer 8

You can replace the lock core in your Thule Excursion rooftop cargo box using their One-Key System Lock Cylinder Kit #TH450200. This kit includes 2 lock cylinders, two keys plus the universal control key that will be used to remove the old core and…

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Answer 9

The Universal Change Key for Thule One Key Locks #853-1251, which is the same as D1251 key you have, is only able to remove unlocked lock cores that have a code beginning with N or E. If you have another code prefix then you will need a locksmith, or…

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Answer 10

The only way to remove a Thule lock cylinder like the ones in #TH450400 is by inserting the master key into a cylinder in the unlocked position. However, I have a few tips and tricks to help you remove the broken key to allow for the master key to be…

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Answer 11

It sounds like you may either need a new lock core or the latch needs to be changed out. We do have the Thule One-Key System #TH450200 which contains 2 new lock cores for both sides of your cargo box with matching keys. A Change Key #853-1251 can be…

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Answer 12

I will need a little more background information if possible. Were you driving through wet/rainy/snowy conditions? If so what was the approximate outside temperature? I have seen new or used cargo boxes, not just the Thule Force XT L #TH6357B, but…

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Troubleshooting New Thule Key that Won't Turn Lock on Cargo Box

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