2004 Subaru WRX STi, 65K miles, with the Brembo Calipers.
Note: this car spent time in Alaska before it came to CA.
I was performing a front brake job (pads and rotors) and the upper caliper bolt (on the driver side) was seized into the caliper body. The bolt is a grade 10 M12X1.5mm bolt that is approx 45mm long. The bolt is steel and the caliper body is aluminum.
Somehow, I was able to remove the bolt without breaking it. The threads on the caliper side were almost gone. I ran my M12x1.5mm tap thru the damaged hole and after a few tries, some threads were "created." You can feel the threads but you can barely see them.
The bolt was ran thru a M12X1.5mm die several times and the threads look okay.
I threaded in the bolt and it went in smoothly. I was able to successfully torque the bolt to 80 ft-lbs.
Clearly, this was not an ideal repair. My questions are:
1) My "repair" allowed the bolt to be torqued to spec. When torquing the bolt, it felt normal. Should I just leave it alone or should I disassemble and repair properly?
2) I do not own a M12x1.5mm time-sert kit but I can buy one. However, would tapping the caliper with a SAE 1/2" die and installing the appropriate size/thread pitch bolt be an acceptable repair?
Some links to this issue:https://forums.nasioc.com/forums/showthread.php?t=874551https://www.iwsti.com/forums/gd-general/236287-attention-anyone-brembo-brake-calipers.html