Post-Accident Repair - Tips and Tricks

[cptj777]

A previous thread talking about my truck and its original attempted write off has been removed as per my request, following severe online threats and harassment from users on X after the story went viral. I will not discuss it here, and I ask you not to. I will not respond to questions about it here.

The original video on YouTube is still there. It too has had its comments turned off. If you really wish to discuss it, Transport Evolved's discord forum is where civil conversations can be had. No, I'm not linking to it, directly to avoid further exacerbation of the original problem, but it's linked to in every Transport Evolved video on YouTube.

I have created THIS thread because I want to give some F150 Lightning owners in similar situations a way of dealing with their repair procedures without the 1 month and a lot of stress that mine caused.

For those who have been keeping track:

Back in February, our F-150 Lightning was in a rear-end collision in California. Someone ran into the back of us while we were stopped at a light. The truck sustained a small crack on the underside of the left-side bumper mount, and a Ford accident repair place in Oregon told us the truck was fine.

It wasn't. A few months later we discovered the crack had grown. We headed to a different repair facility, who ordered the wrong part, then claimed the only repair procedure was to replace the entire frame — which caused the insurance company to attempt to write the truck off. In our case, I was able to reach out to some contacts at Ford, which resolved the problem completely. I was able to not only get the write-off decision reversed, but the repair authorized.

Here's what you need to know:

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!

Thanks for keeping everyone informed on the process and how it turned out! That phone number is a good resource to have.

Sponsored

 

[Aminorjourney]

A follow up video is on our YouTube channel and website. Not linking here.

 

[Wendy]

Ditto to all the things others have said … one thing I wanted to add that I don’t think has been expressed.

I was sad when reading your story to think you would no longer have a Lightening and would no longer be providing posts on our Forum!

Glad to have you back / here

 

[TaxmanHog]

Ford Authority coverage...........

https://fordauthority.com/2026/06/b...ford-f-150-lightning-after-minor-crash-video/

 

[MaintGrl]

Ford Authority coverage...........

https://fordauthority.com/2026/06/b...ford-f-150-lightning-after-minor-crash-video/

Must be the video, made reference to earlier...
Relevant to me on so many levels....
Thank you TaxmanHog

 

[Aminorjourney]

Must be the video, made reference to earlier...
Relevant to me on so many levels....
Thank you TaxmanHog

Happy to see the word getting out. The way this body shop behaved was just way out of line.

The rest? Well, they didn't get taught any love and compassion as kiddos.

 

[Newton]

Thread cleaned of OFF TOPIC contributions
Focus people ..... FOCUS!

Don't you mean "Lightning"?

 

[Zprime29]

Ford Authority coverage...........

https://fordauthority.com/2026/06/b...ford-f-150-lightning-after-minor-crash-video/

Did I gloss over it? No where in the article do they inform the reader that anyone can reach out for assistance. After a quick skim, the impression I get from the article is that you have to know someone who knows someone to get help.

+1,000 to @Aminorjourney for taking the extra step and providing valuable information and improving the community.

 

[ka-chow]

According to that story....

"The Ford F-150 Lightning like Gordon-Bloomfield's is no longer in production, slashed due to waning interest in all-electric vehicles."

Oh, was that the reason?

Ford Authority coverage...........

https://fordauthority.com/2026/06/b...ford-f-150-lightning-after-minor-crash-video/

 

[Aminorjourney]

According to that story....

"The Ford F-150 Lightning like Gordon-Bloomfield's is no longer in production, slashed due to waning interest in all-electric vehicles."

Oh, was that the reason?

I'd share a screen shot disproving the claim, but I'd get in trouble for being political

 

[ka-chow]

Well my response was certainly meant to be very sarcastic. Haha

I saw that and was instantly triggered.

I'd share a screen shot disproving the claim, but I'd get in trouble for being political

Sponsored