Post-Accident Repair - Tips and Tricks

1. Ford has a dedicated team at its headquarters whose job is specifically to work on bodywork and repair procedures for their vehicles. They're the ones who design and write repair procedures for the accident repair world. If a repair procedure isn't already available, they're the ones who may be able to provide one.
2. The Lightning DOES have different parts to regular F-150s on some components, including the chassis. In my case, the rear bumper mount — a commonly-replaced part on gas F-150s — was the broken component. The repair shop wanted to follow ICE F-150 repair procedures, but since the Lightning-specific part isn't easily available right now, and they did minimal research, we ended up where we did. Additionally, even though the original insurance adjuster said they thought welding the crack back up would be the appropriate repair, the repair shop wanted to ONLY replace the part - and when they couldn't they claimed a new frame would be required.
3. Repair shops and insurance companies will do the ABSOLUTE MINIMUM to figure out a repair. If a repair procedure isn't available, or the part isn't available, they WILL write the truck off unless you get actively involved.
4. Ford HAS a repair line that repair centers can call for advice. They will look at photos, assess the damage, and advise on repair procedures. This is how my F-150 Lightning was saved. I reached it through my contact at Ford — not through conventional means. That said, body shops AND insurance companies SHOULD be using this resource. They don't. You need to push them to do so at 1-800-327-8281. (US and Canada). This line can direct shops to the nearest Ford Certified Collision Network center, provide repair guidance, and connect them with Ford's specialist team. If your repair shop hasn't called this number, push them to do so before accepting any total loss determination.
5. In my case, after my intervention, I was able to get Ford's team to call my repair garage AND my insurance company and explained the official repair procedure. They provided a written email outlining exactly what was to be done, approved as officially sanctioned by Ford Motor Company. Get it in writing. Always. What Ford said would be 'acceptable' was not what the insurance and repair centre wanted. THEY WOULD NOT HAVE ACCEPTED THE REPAIR WITHOUT FORD'S SANCTIONING.
6. Exactly what is "allowed" will depend on your insurer and where you live. I'm in Oregon, where the rules around chassis integrity are particularly strict. Less so in most other U.S. states. Canada also has some fairly strict rules in certain provinces. I can't speak to Australia or Europe, but I understand some jurisdictions have strong rules as well.
7. In my case, the approved repair was straightforward: drill a stop hole at the end of the crack, V-groove the edges, fill with a solid MIG weld, grind and dress the repair, apply corrosion protection, and cavity wax the inside of the rail. That's it. Simple, cheap, and Ford-sanctioned. Your repair may differ depending on the damage, but the point is — it was fixable. Don't let anyone tell you otherwise without exhausting every avenue first.
8. Once you have Ford's written approval for a repair procedure, your insurance company has very little grounds to refuse it. That document was the thing that reversed the total loss decision in our case. I'm writing this before the repair has been completed, and I understand the repair centre is STILL DRAGGING THEIR FEET - so make sure if this happens to you, you keep ALL DOCUMENTATION AND PHONE RECORDS!

FloridaMan655321 said:

Always interesting when comments are turned off

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MountainAlive said:

Appreciate the detailed write up and Ford phone number for the repair shops to call. I’m still not 100% clear on where I should insert myself in the whole process to prevent a premature “totaled” declaration, but knowing this can be challenged is the key.

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