Troubleshooting A New Thule Lock Core That Won't Seat Completely After Drilling Out Old Core

Question:

I drilled out the lock core on my Thule Pulse M because I couldnt remove a broken key. I ordered a new core and master key but couldnt it all the way because the lock was in the locked position. I sent a picture with the question. He responded that it could be due to debris in the hole, but it also looked like the hole may have been damaged by the drilling. He also said if the hole was damaged then the entire item would need to be replaced.inch I replied to his email and asked: by entire iteminch did he mean the whole lock mechanism, or the Pulse M rooftop carrier itself? He didnt respond so Im not sure what to do next. Thank you.

asked by: Bruce T

Helpful Expert Reply:

It looks to me that there may be some debris at the bottom of the lock core that could be possibly obstructing your new lock core from seating properly.

I would start by attempting to clean the debris out with a nylon brush # 814092 and trying to seat the new lock core again.

I did also reach out to Thule and they mentioned that there also might be a chance that the hole could've been damaged when you drilled out the lock core.

If that's the case, then the entire item would need to be replaced, unfortunately. If you let me know what you have I'd be happy to find a replacement for you.

expert reply by: Bryce D

Damaged Lock Core Hole
(click to enlarge)

Bruce T.

10/13/2022

Bryce D.

10/13/2022

Sorry about the confusion! When I mentioned that the entire item would need to get replaced, I was referring to the entire rooftop cargo box. Since the Thule Pulse Medium Rooftop Cargo Box # TH614 is a pretty new cargo box, you could just replace it with the same model. If you wanted to use this time to upgrade your box to a larger box, the Thule Pulse Large Rooftop Cargo Box # TH615 is a great option that features 2 more cubic feet of storage space.