How to Replace Lock Cylinder with Broken Key on Thule Cascade XT Roof Box

Question:

Key broken off in cylinder. Cannot remove cylinder in order to replace with new cylinder and key on my Thule Cascade XT.

asked by: Darwin T

Expert Reply:

To remove a Thule lock cylinder like the one on your Thule Cascade XT roof box the master key must be inserted into the cylinder and it must be in the unlocked position. That being said, I'll share some tips that will hopefully allow you remove the broken key so you can insert the master key and replace the cylinder.

First, spray a generous amount of oil lubricant into the key hole. Your key was most likely hard to operate before it broke so the lubricant will help the key slide out a bit easier.

Next, we need to make sure the lock is completely in the locked (vertical) or unlocked (horizontal) position. If the key broke off while it was partially turned, you'll need to align it before it can slide out. You can use a flat head screw driver to try to turn it.

Once aligned, try using a pair of needle nose pliers to pull the key out. You may need to try this a few times as it may not come out on the very first try.

If you're still unable to slide the key out you can try using a jig saw blade. With the blade's teeth pointing up, slide it alongside the key and wiggle it until you feel it grabbing one of the mechanisms inside. Gently pull out the blade; the key should come out with it.

If none of this works, your only other option is to drill the lock out being very careful not to cause any damage to the cylinder housing. Once this is accomplished, you can use the Universal Change Key included in the Thule One-Key System Lock Cylinders # TH450200 to replace the locks and keys.

You can check out the video I attached which shows how to use the master key to remove a Thule lock cylinder. Good luck!