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How to Remove or Change a Roof Rack Lock Barrel Easily

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15.11.2024

Changing or removing the lock barrel on your roof rack may seem like a daunting task, but it’s actually simpler than you might think. Whether you need a replacement due to a lost key, wear and tear, or just want to swap out an old lock for a new one, following the right steps can make the process hassle-free. This guide will walk you through everything you need to know about handling a roof rack lock barrel with ease.

Why You Might Need to Change a Roof Rack Lock Barrel ?

There are several reasons why you may want to replace or remove your roof rack lock barrel:

  • Lost Key: If you've misplaced the key, replacing the lock barrel is often the most practical solution.
  • Upgrading the Lock: Maybe you want a more secure lock for added peace of mind.
  • Routine Maintenance: Over time, lock barrels can wear down, making it harder to insert or turn the key.
  • Uniformity: If you've recently changed your car key, you may want to match your roof rack lock with it.

Knowing why you’re changing the lock barrel will help you determine the steps you need to follow.

What You’ll Need

Before you start, gather these essential tools and items:

  • Replacement Lock Barrel: Ensure it’s compatible with your roof rack model.
  • Master Key or Removal Key: Often required to remove the old lock barrel.
  • New Key: The key that corresponds to the replacement lock barrel.
  • Flathead Screwdriver: To gently pry and release certain parts if needed.

Step-by-Step Guide to Removing a Roof Rack Lock Barrel

Removing a lock barrel from your roof rack doesn’t require extensive mechanical skills. Just follow these straightforward steps:

1. Locate the Lock Barrel

The lock barrel is usually situated in the center or side of the roof rack. Look for the small lock with the keyhole, as this is where you'll be inserting the master or removal key.

2. Insert the Master Key or Removal Key

If you have a master or removal key, insert it into the lock. This is often a universal key provided by the lock manufacturer specifically for removing lock barrels. Once it’s inserted, turn the key slightly to unlock the barrel.

Tip: If you don’t have a removal key, contact a professional or see if you can order one specifically for your model.

3. Pull the Lock Barrel Out

With the removal key still in place, gently pull the lock barrel out. If it’s resistant, try wiggling it slightly while pulling. Avoid forcing it, as this could damage the lock or roof rack. In some cases, you may need a flathead screwdriver to help pry it out, but be careful not to scratch the surrounding area.

4. Check the Casing

After removing the lock barrel, inspect the casing where the barrel was installed. Make sure it’s clean and free of debris. Any dirt or rust could interfere with the new lock barrel, so it’s a good idea to clean this area before proceeding.

Installing the New Lock Barrel

Once the old barrel is removed, you’re ready to install the new one. Here’s how:

1. Align the New Lock Barrel

Take your new lock barrel and align it with the casing where the old one was. Most barrels are designed to fit in only one direction, so make sure you align it properly to avoid jamming.

2. Insert the New Barrel

Push the new lock barrel into the casing until it clicks into place. This might require a bit of pressure, but it should fit snugly without needing excessive force.

3. Test the New Key

After installing the new lock barrel, insert the new key and turn it to ensure it’s working smoothly. The key should turn easily and lock securely. This step verifies that the new lock is properly aligned and functional.

Common Challenges and Solutions

While changing a roof rack lock barrel is generally straightforward, you might encounter some challenges. Here’s how to troubleshoot common issues:

  • Stuck Barrel: If the old barrel is stuck, apply a lubricant like WD-40 around the lock to help loosen it.
  • No Removal Key: If you don’t have a master or removal key, consider reaching out to a locksmith or checking if the manufacturer offers a replacement.
  • Barrel Won’t Fit: Ensure you’ve purchased a compatible lock barrel. Even slight differences in design can prevent it from fitting properly.

Tips for Maintaining Your Roof Rack Lock

To keep your new lock barrel in good condition and prevent the need for frequent replacements, consider these maintenance tips:

  • Regular Cleaning: Dirt and grime can accumulate inside the lock over time, making it harder to operate. Clean the lock regularly to prevent this.
  • Use Lubricant: Apply a small amount of lubricant inside the lock barrel periodically to keep the key turning smoothly.
  • Protect from Rust: If your roof rack is exposed to rain and humidity, use a protective cover or shield to keep moisture out of the lock barrel.
  • Check Key Fit: Avoid using a damaged or bent key, as this can wear out the lock barrel more quickly.

When to Seek Professional Help

In some cases, removing or replacing a roof rack lock barrel might require assistance from a professional:

  • Lost or Damaged Keys: If both your main key and master key are lost or damaged, a professional can help retrieve or replace the lock barrel.
  • Damaged Lock Mechanism: If the lock itself is damaged or jammed, forcing it can make things worse. A professional locksmith can safely remove and replace it.

Replacing or removing a roof rack lock barrel is an affordable and manageable task for most car owners. By following the right steps and keeping up with regular maintenance, you can ensure your roof rack lock stays functional and secure. Whether you’re upgrading for security or replacing a worn-out lock, a new lock barrel can make all the difference in keeping your roof rack safe.

Effortless Key Replacement for a Variety of Locks

Order 2x Union Keys FT Series, custom-cut to your original key code, for a hassle-free replacement. Compatible with a range of locks, including those from Aston Martin, Jaguar, Land Rover, and more, these keys are perfect for classic cars, caravans, petrol caps, roof racks, and truck canopies. Simply find your lock code (e.g., FT101-FT360) on the lock face and enjoy fast delivery of high-quality spare keys.

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As RAC advise, this step often resolves the problem without cost. b) Search systematically Check all pockets, bags, seats, coat hangers, beach bags, under cushions, in and around your car. If you’re staying somewhere temporarily, check hotel rooms, fuelling stations, parking lots. As one travel-site suggests: “Go through all your pockets… look around all surfaces in your hotel room”. c) Contact places you visited Call restaurants, cafés, shops, airport parking or hotels where you parked the vehicle. Key finders are often handed in. d) Assess risk of theft If you suspect the keys were stolen (pick-pocket, hotel burglary or unattended vehicle) you should alert local police and your insurance provider—once a key is missing, your vehicle security is compromised. e) Secure the vehicle If the vehicle is parked in an insecure location, consider moving it (if possible) or arranging towing. Leaving it locked but unattended increases theft risk. 3. How to use replacement key delivery services Replacement key delivery refers to services that cut and program a new car key and deliver it (or have it fitted) to your location—whether your holiday base, airport car park or home driveway. Steps to follow: Have vehicle details ready: make, model, year, registration number, VIN if available. Choose service: For UK and travel users, many auto-locksmiths offer mobile services that come to you. Confirm delivery logistics: Where is the vehicle parked? Will you be present when the key is delivered or fitted? If abroad, is the company able to support your location? Understand key type: Basic mechanical, transponder chip key, keyless fob—all vary in price and logistics. Check old key de-activation: A top provider will delete the lost key’s code so it cannot be used in future—critical for security. Why this is often your best path while travelling Going via your vehicle manufacturer dealer is often slower and pricier — as UK guide notes: “The quickest and least expensive way … is via an auto locksmith.” In a foreign locale, a mobile specialist or key-delivery service saves towing the vehicle and waiting for factory part shipment. 4. Hiring an emergency locksmith: what to look for When you’re locked out or stranded, an emergency locksmith (24-hour) can be your lifeline. But not all are equal. Checklist: Confirm they specialise in auto locksmith / car key replacement , not just domestic locks. Ask for credentials (affiliation with industry body). Insist on proof they will delete/pair the key to your vehicle (so lost key becomes useless). Understand travel/overseas call-out charges. Before arrival, ask for an estimate and payment process (card, cash etc.). Some holiday locales only accept cash. Stay with your vehicle in a safe public place. If you are on a remote vacation site, move to well-lit area before the locksmith arrives. Typical process: The locksmith arrives, verifies ownership (ID + logbook/V5C). They cut and/or program a key, or fix the lock/immobiliser if required. You pay for service and receive the new key — vehicle is back on the road. 5. Insurance, roadside cover and overseas travel issues Insurance/key cover Do you have lost key cover? Most UK car insurance policies don’t include lost keys as standard. You might need a premium add-on. If you claim, your no-claims bonus may be affected. Breakdown/roadside assistance Your breakdown provider (e.g., Motorway or RAC ) may offer key services, but often their vans don’t carry full key-programming equipment. So an auto locksmith still may be needed. Travelling abroad Check if your insurance/cover extends to the country you’re in. Confirm language support and local currency charges with any service you call. If you rented the car: contact the rental company immediately — they may have specific protocols for lost keys (often expensive). 6. Special cases: rental vehicles, keyless entry & fobs Rental vehicles When you lose the keys to a hire car abroad, you are likely to be liable for high fees. Rental companies will likely charge for towing and replacement, not just the locksmith. According to travel forums: “We do not offer coverage for lost keys… The replacement fee of $125 for lost key.” Call the rental agency, follow their instructions, and keep all receipts. Keyless / smart keys & modern cars Most vehicles since 2000 use transponder chips or keyless systems. Replacement these can cost several hundred pounds—UK guides show typical range from £100–£300 or more depending on brand. When you lose a keyless fob, you may need the original still in possession or need the vehicle brought to the dealer. Factor this potential delay into your travel plans. Single key left If you only have one remaining key, treat it as your last key. Get a spare made ASAP once you’re home so you’re not in the same situation again. 7. Preventative measures for your next trip Always carry a spare key at home or with a trusted person. Use a tracker (such as an AirTag or Bluetooth key-tracker) on your keyring. UK blogs suggest this simple tech helps locate lost keys. Establish a routine spot where you place your keys at the start of every journey. If you have old keys (house + car), don’t mix them during travel. Note down your vehicle details (make, model, registration, VIN) in your phone before travelling—so you’re ready if you need a replacement. For holiday car hire, take a photo of the key and keep the rental company’s emergency phone number saved. FAQ Q: What happens if I lose my only car key and I’m abroad? A: You’ll need to contact an auto locksmith or dealer who can cut and program a new key. Have vehicle details ready. Expect cost and waiting time to increase since you have no spare. Q: Can I just use a dealer to replace the key? A: Yes, but often it’s slower and more expensive . UK guides claim mobile auto locksmiths are typically faster and cheaper. Q: How long does replacement take? A: For many modern cars, the physical key can be cut quickly, but programming and blank arrival may take days. Dealers might take up to weeks. Q: Will my car insurance cover a lost key? A: Only if you have key-cover added or your insurance includes it—not standard. Check your policy. Claiming may affect your no-claims status. Q: What should I do if I lose the key and my car is locked in a remote place? A: First make sure you are safe. Then use your breakdown/roadside cover to move the vehicle to a safe area if needed. Then call an emergency auto locksmith to attend and provide a replacement. Need a reliable solution now? Visit our shop at mr-key.com to discover how we can cut and deliver replacement car keys swiftly—even when you’re travelling.

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