Troubleshooting Thule Lock Core That Will Not Release From Lock Housing

Question

Question:

Any tricks to get the core to easily come out after ing the D1251 key? I cant get the core out of the replacement arm or on my easyfold xt..

asked by: James

1

Helpful Expert Reply:

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 you can try drilling out the lock core yourself.

If you indeed have N or E at the beginning of the code and the change key still won't remove the lock, then make sure the core is unlocked and spray some lubricant to free up the lock. Then insert the change key and wiggle it around a little bit to try and break the core out of the housing. You may even try tapping the key with a mallet to help free up the lock. Last resort would be to drill out the lock core or take it to a locksmith as mentioned above. I attached a demonstration video for you.

expert reply by: Andrew N

1

Answer 1

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…

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Answer 2

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 3

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 4

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 5

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 6

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 7

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 8

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 9

If the lock cylinder on your Thule Excursion Cargo Box is in the unlocked position you can just use the Universal Change Key, #853-1251, to remove the current cylinder and replace it with a new one, part #THLOCKN022 and #THKEYN022. If the box is…

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Answer 10

If you look at the lock core on your Thule Excursion cargo box you will see a number stamped on it. With that info we can easily pick out the correct replacement key as a Master key would not work. A Master key can only remove an unlocked cylinder…

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Answer 11

We can help you with replacement keys for your Thule bike rack. Thule products use coded lock cores and the number code on your lock will tell you which key to order. Please refer to the linked photo that illustrates a lock core. You will use partial…

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Answer 12

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…

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Troubleshooting Thule Lock Core That Will Not Release From Lock Housing

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