I recently purchased a 2006 Ford Freestar and I am checking all fluids. The master cylinder is tucked under the cowl; I can't even determine the fluid level. That black plastic cowl cover that is around the wiper arms may provide access if removed. Is that correct? If not, how best to check and fill reservoir? Thanks

I can't imagine changing the spark plugs on the backside of that transverse mounted V6.

 

A suggestion;
Check the braike pads for wear. As the pads wear the level in the master cyl goes down.
If half worn , you might add some DOT3 brake fluid, but the next time it starts to look like it might be getting low , good chance pads could be due for replacement.

 

I pulled both front wheels; both inner and outer pads have about 4 mm remaining.

I would like to get access to the master cylinder reservoir to get a good look at fluid level, and to top off the DOT3 if needed. Do you know if removal of that cowl panel will provide access?

Thanks

 

It should.

If the thickness of the pad material equals the thickness of the steel backing, that is the time to replace the pads.

 

There's no easy way to check or top off. Can you imagine what it takes to replace the master cylinder or booster?

To make it easier to check, you can use a telescoping mirror and using a funnel having a hose attached will make minor topping off of the fluid easier. Small top offs are normal as the pads wear but large top offs require further investigation for leaks or worn out linings.

 

I measured the pad thickness using a shim; 4 mm does not include the steel backing. Thanks

 

I just went through this same thing, I absolutely have no clue as to what the Ford design engineers were thinking. I guess they weren't thinking. Anyway, there are 2 black plastic pieces running between the windshield and the engine compartment. If you take both of them off you can easily access the maste cylinder. You will need 7, 8, and 15mm sockets and a body panel removal tool. You will have to remove both windshield wiper arms and then using the body panel tool you will pop the top piece loose. The connectors are spaced along the edge adjacent to the windshield. Once that panel is removed it exposes the bolts holding the second panel in place. Remove the 2 bolts on each end, the 4 bolts around the passenger side wiper arm, and the bolts attaching the cabin airbox to the panel. Remove the panel and you can get to the master cylinder.

Good luck

 

Thanks; I used a kitchen baster with a hose attached to remove fluid when compressing the pistons into the calipers. I was surprised that the front calipers are dual piston. I used a hose on a funnel to add some fluid back into the reservoir. Ford should have provided an access panel if they couldn't find a way to make it otherwise accessible.