Repair Documentation and OEM Procedure Research
Objective. Students will research and compile a complete OEM-compliant structural repair package—including procedure documents, position statements, and pre/post measurement records—for an assigned collision scenario.
This lesson, its worked examples and its practice questions has not yet been verified by a certified examiner or master technician in the trade or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.
VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.
Why OEM Procedures Are the Starting Point
When a vehicle sustains structural damage, every repair decision must trace back to the original equipment manufacturer (OEM). Automakers design vehicles with engineered crumple zones, high-strength and ultra-high-strength steels, aluminum structures, and mixed-material assemblies. Those design choices dictate exactly how a repair must be performed. Deviating from OEM procedures can compromise crashworthiness, void warranties, create liability exposure for the shop, and—most importantly—endanger the vehicle occupants in a future collision.
Both I-CAR and ASE B-series standards recognize OEM procedure compliance as a foundational competency. Insurers, collision repair networks, and certified shop programs increasingly require documented evidence that OEM guidance was followed.
Information Systems: Where to Start
Three primary channels deliver OEM structural repair information:
- Direct OEM portals – Manufacturers such as Ford, GM, Toyota, and others publish repair procedures on their own subscription-based websites. These are the primary source and are always the most current.
- Mitchell Diagnostics / Mitchell RepairCenter – Aggregates OEM data and links repair procedures within the estimating workflow.
- AllData Collision – Another aggregator providing access to OEM body repair manuals, position statements, and weld specifications by VIN or year/make/model.
When you open a structural repair file, always verify the VIN to confirm the exact model year, trim level, and plant of manufacture. A mid-year production change can affect steel grade, adhesive type, or sectioning location. Never assume a procedure from a similar model applies.
What to Locate in the Information System
For any structural repair package you must find and print:
1. Body Repair Manual (BRM) procedure – Step-by-step disassembly, straightening limits, sectioning locations, welding method (MIG, squeeze-type resistance spot welding, or MIG-plug weld count and spacing), and reassembly sequence.
2. Sectioning guidelines – Where cuts are permitted, where they are prohibited, required overlap lengths, and weld schedules.
3. OEM position statements – Manufacturer statements on topics such as whether a component is replace-only (never repaired), restrictions on heat application to ultra-high-strength steel, and approved repair methods for aluminum or boron-steel parts.
4. Material specifications – Steel grade at each location, approved filler wire or electrode, structural adhesive part numbers where applicable.
5. Corrosion-protection requirements – Anti-corrosion compound application areas, weld-through primer requirements, and sealer/deadener replacement instructions.
Pre-Repair Measurement Documentation
Before any metal is moved, record a complete set of datum-plane and centerline measurements using the vehicle manufacturer's specified measurement points. These baseline readings prove the extent of damage and establish the target dimensions the structure must return to. Common measurement systems include universal dedicated fixtures (frame racks with dedicated tooling) and computerized three-dimensional measuring systems.
Document:
- Measurement system used and its calibration status
- All control points measured with actual vs. specification readings
- Photographs of damage with a measuring scale visible
- A damage diagram showing direction and estimated severity of force
Assembling the Repair Package Folder
Organize documents in a logical, professional order that any technician or inspector can follow. A common industry sequence:
1. Cover sheet – Vehicle ID, VIN, date, assigned technician
2. Damage diagram and pre-repair photographs
3. Pre-repair measurement record
4. Applicable OEM position statements
5. BRM structural repair procedure printout
6. Sectioning guidelines (highlighted to the relevant sections)
7. Material and weld specifications
8. Corrosion-protection plan with product identification
9. Post-repair measurement record (completed after repair)
10. Post-repair photographs
Estimating platforms such as CCC ONE and Audatex (Solera) have established documentation conventions; your package format should mirror those conventions so it integrates smoothly with the shop's estimating workflow.
Safety Considerations
Researching procedures is an office-environment task, but the decisions made here directly control safety in the shop:
- PPE review – The corrosion-protection plan must identify the correct respiratory protection (supplied-air or appropriate cartridge respirator) for any coatings or adhesives specified by the OEM.
- Lockout/Tagout (LOTO) – Procedures involving hybrid or electric vehicles must include instructions for high-voltage system de-energization before any structural work begins. OEM procedures will specify this; your package must include that page.
- Material Safety Data / SDS access – Any adhesive, sealer, or coating identified in the package requires the corresponding Safety Data Sheet to be accessible in the shop.
- Do-not-heat warnings – Many OEM position statements prohibit heat on ultra-high-strength boron steel. Your package must flag these restrictions clearly so no technician applies heat where it is forbidden.
Post-Repair Measurement and Close-Out
After straightening and sectioning are complete, repeat all measurements at the same control points and record actual achieved dimensions against OEM specification. Both pre- and post-repair records must be in the package. This documentation demonstrates that the structure was returned to within manufacturer tolerances and provides a legal record of the repair quality.
Peer Review
Reviewing a classmate's package sharpens your own eye for completeness. Use the scoring rubric systematically: check that every required document is present, that procedures match the specific VIN, that weld specifications are correct for the steel grade, and that pre/post measurements are fully recorded. Written feedback must be specific—note the page or section where something is missing or incorrect, and cite the OEM procedure that should have been used.
Key terms10
Materials: Computers with OEM information system access (Mitchell, AllData, or direct portal), printer, repair package rubric, industry estimating format guide (e.g., CCC or Audatex documentation conventions)
Check: Repair package evaluated against rubric; must include all required documents, correct vehicle-specific procedures, and complete pre/post measurement records; pass mark 80%
Practice check8
Answer each question, then check it. Nothing is recorded; this is your own practice.
