This guide describes how you to fit 306 GTi brakes & calipers on a 106. All parts were fitted to a 1993 106 XSi 1.4 but this guide should be the same/similar for all of "sporty" 106's.
Before you even start it would be a good idea to have some 15" wheels as the discs are too big to fit under the standard 14" rims found on most 106's as standard.
DISCLAIMER: The following quick guide can ruin your car! Beware that you have to read/view the article very well.
www.Peugeotperformance.net nor the author is responsible for any damages caused to your car when you follow the steps written in this article.
The 306 GTi calipers can be bought from a scrap yard or you can buy them new from Peugeot dealer.
The prices for the parts from a scrap yard seem to range from around £150 right up to £250 for the calipers and carriers. Be sure to buy new discs and pads if you are getting the parts from a scrap yard.
Once you have the following parts you can make a start. Before I started fitting the calipers (from scrap yard), I had them first sandblasted and then powder coated which you will see in the images below!
Most engineering type places will be able to sand blast them for you.
Firstly you will need to take off the standard calipers and discs, its easier to do one side at a time.
Open up the bleed valve and give the pedal a few pushes so that you can then take off the caliper easier.
Use some sort of container or a brake bleeding kit to catch the fluid in as its not nice stuff.
If you don't know what/where the bleed nipple is I suggest you buy an Haynes manual or let someone else do it for you!
Once you have drained the fluid out you can start to un-do the caliper from the hub.
Once you have un-done the bolts at the rear of the caliper un-screw the brake line from the caliper.
Now take the disc off of the hub.
The calipers off of the 306 will not fit straight onto the 106 without a slight bit of machining.
The pictures above showe exactly what needs machining.
It is the caliper carrier that needs a slight alteration as you will see if you offer it up to the hub.
The top inside corner requires a small area grinding off to allow it to sit properly when bolted in place.
I used a grinding wheel to carry out the necessary alterations and then various grades of wet and dry paper to smoothen the edges off.
It is easier to do a bit at a time and then check if it will fit onto the hub properly.
Once all the alterations have been made to the carrier, place the new disc in place and bolt the caliper onto the hub using the bolts made for the 306 caliper.
I was lucky enough to get these bolts when I bought the calipers.
If not then the main dealers should sell them.
You will need to use these bolts as the 106 bolts are too long.
Before putting the brake pads on you should smear a little bit of copper grease onto the back of the pads to help movement and stop squeeling.
Place the pads into the carrier and hook up the "wear sensors".
Allways make sure you replace all the discs and pads if you bought them 2nd hand.
With the carrier now on and the caliper ready, put some "Copper grease" on the sliders of the caliper as this will aid the movement and help stop them sticking.
The sliders can be seen in the picture above.
With everything now in place its a simple matter of replacing the brake hoses if you purchased replacement braided hoses.
A lot of people recommend braided hoses as it helps the pedal feel.
Follow all the above steps again for the opposite side, then bleed the entire system as described in the haynes manual.
It is important that you bleed the brakes in the correct order as described in the manual.
After you have fitted the brakes you should try to avoid hard braking for approximately 200 miles in order to bed the brakes in properly.
You will probably notice the pedal travel is slightly longer than it was with the standard brakes, this will get better as the brakes bed in.
If there is a spongey feeling to the pedal there is probably still air trapped in the system so re-bleed the whole system again.
You can use the master cylinder off of a 406 which will help reduce the brake pedal travel, but you soon get used to the travel anyway.
Above are a couple more pictures of the brakes fitted.
You can clearly see the brakes a lot larger than standard and one picture shows the reason for 15" wheels being a requirement.
The 306 GTi caliper only clears the inside of the wheel by a couple of cm's.
