Broken/snapped caliper bolt

[CaboRunner]

I'll give it a whirl.

Taking the safer assumption the OEM bolt is M10, the Time-Sert kit comes with a 13/32" drill bit (0.40625" diameter). I've clunkily drilled with a 5/16" bit (0.3125"), so I figure I can go up to a 3/8" (0.375") safely without impacting the ability to put in a Time-Sert. FWIW, I haven't read any horror stories with Heli-Coils, but the general sentiment is Time-Sert is made from more durable components, and given the bolt is holding the freaking brake caliper in place, I'm not taking any chances. The additional ~$60 is worth my life .

Timeserts are much better! Easier to install with the countersink bit and stronger. Try Fastenal, they have stores everywhere and have most things in stock. You can probably buy just the drill bit and one insert instead of a whole kit

 

[varol1]

I wanted to close the loop on this thread.

After what seemed like an insurmountable amount of time drilling and never-ending trips to the hardware store for new drill bits, I was able to finally drill out the old bolt and install the TIME-SERT. I had to eyeball the angle as best as I could; I also had to use a socket wrench with the tap as there wasn't enough clearance with a T-bar.

After getting everything put back together, I took a deep breath and went to turn the driver-side front wheel by hand, only to realize it only went around half a turn. Recalling an earlier post about OEM wheels not fitting over the Tundra calipers (even though research had led me to believe otherwise) and ready to cry, I took a closer look from the inside of the wheel and realized there were wheel weights hitting against the caliper. After verifying the rear wheel used a different type of weight, I swapped them around and was able to turn the wheel all the way.

I didn't use Loctite on the TIME-SERT (but realized after the fact I had an unopened tube of it) though hopefully it won't be an issue. I also wasn't able to fully torque the bolt through the TIME-SERT and backed off of it when it clearly started turning with lesser effort. I've since gone on a road trip with three other passengers and haven't had any issues, so suffice it to say the effort paid off in the end.

Thanks again to everyone for all the help and suggestions. You guys are the best.