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Can't open or lock Thule 200 polar with key

Key is in lock will not turn, will not come out, will not lock or open. Box is not on car or filled.

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Posted on Jan 02, 2017

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SOURCE: How to change locks?

Just replaced the locks on an Atlantis 200 which should be the same.
Pop off the 3 rubber caps around the lock and drill out the rivets.
Inside the box pull the plastic unit away from you (bending the aluminium strip slightly but this is fine) gaining access to 2 screws. Unscrew these (I used a small ratchet with a pozi bit rather than a screwdriver) and remove the plastic unit.
You'll have to take out the lock cartridge next. Theres various wedges in the plastic which you should try to hold open then a flat screwdriver near the cog should lever the whole thing out.
To get the barrel lock out of it's cartridge you'll have to push the tumblers in from the back with a very small screwdriver and gradually work it out. (the one I did had a snapped key so I'm assuming this part is easier if you are just changing locks for keyed alike purposes)
Fitting the new lock in to it's cartridge should be easy enough. When you reinsert the cartridge in to the housing make sure that the sliding bolt (that your key turns) is fully in the open position, otherwse your key won't do a thing.
Screw the housing back on and re-rivet the points you drilled.

Dan (Rothwell Trailers)

Posted on Sep 07, 2010

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May need to be reprogrammed:
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I know this is old but there doesn't seem to be much on the web about this common problem. If your roof box lock appears to be jammed, key stuck in, broken off etc here is my advice based on what happened to mine. Basically the issue is not the lock but the sliding locking bar inside the box, when you lock or unlock the lock you are just turning a small Lever inside the locking bar mechanism which slides the locking bar left or right to clamp or release the 3 hinge pins on the lid. The locking bar slider is aluminium, about 4 feet long and a lot for the little key to move, especially when dirty, clogged with sand etc. I'm my case both sides were seized solid - it was assumed that the locks themselves were seized solid these were forced until the keys snapped off. One bit I picked out with a paper clip, the side I had to drill the whole barrel out. Fortunately my lid was open so I was able to free the sliders inside - wd40, gently tapping the end of the slider back and forth until it was free. New lock barrel, sorted!

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Hinge Replacement, Thule Thule Atlantis 688T 2100 Cargo Cariier


Hi Erroll,

What I believe you're referring to is the 'locking hook' -- the piece attached to the lid that slides into the lock mounted on the bottom segment of the cargo box. While it acts like a hinge in respect of the closed side of the Thule, what the mfg refers to as the hinge (or also referred to as a strut) is the spring mechanism at the front and back used to hold the lid up.

You can acquire this locking hooks online - attached a link for your convenience.

Good luck.

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1 Answer

Lock is jammed


Spray some WD-40 into the keyhole in the lock and wait a few minutes for that to set in. Then try to turn it again. If that doesn't work, the lock cylinder may not be inserted completely. Use the removal specific "key" that comes with Thule locks to pull the lock cylinder out, then reinsert the cylinder completely before removing the removal "key".

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1 Answer

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1 Answer

How to change locks?


Just replaced the locks on an Atlantis 200 which should be the same.
Pop off the 3 rubber caps around the lock and drill out the rivets.
Inside the box pull the plastic unit away from you (bending the aluminium strip slightly but this is fine) gaining access to 2 screws. Unscrew these (I used a small ratchet with a pozi bit rather than a screwdriver) and remove the plastic unit.
You'll have to take out the lock cartridge next. Theres various wedges in the plastic which you should try to hold open then a flat screwdriver near the cog should lever the whole thing out.
To get the barrel lock out of it's cartridge you'll have to push the tumblers in from the back with a very small screwdriver and gradually work it out. (the one I did had a snapped key so I'm assuming this part is easier if you are just changing locks for keyed alike purposes)
Fitting the new lock in to it's cartridge should be easy enough. When you reinsert the cartridge in to the housing make sure that the sliding bolt (that your key turns) is fully in the open position, otherwse your key won't do a thing.
Screw the housing back on and re-rivet the points you drilled.

Dan (Rothwell Trailers)

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1 Answer

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The odds of someone here being able to solve your problem is near zero. Why not go to Thule.com or call using this info:
Thule com Phone Number

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its probably because you keep the key turned for too long while locking the car.
turn the key to lock it and turn back again quickly.
It freaked me out the first time it happened me but once you get used to it, its not a big deal

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