Harry’s Auto Collision is a family-owned, award-winning auto body repair shop operating in Los Angeles and Thousand Oaks, California, since 1974. They specialize in repairing luxury, exotic, and electric vehicles (including Lucid and Tesla), providing services such as structural repairs, paint refinishing, ADAS calibration, and insurance claim support.
- Electric vehicle (EV) collision repair differs significantly from internal combustion engine (ICE) vehicle repair because EVs integrate high-voltage battery systems, aluminum-intensive structures, and advanced driver-assistance systems (ADAS) directly into their design.
- Many EVs use a skateboard platform where the battery pack forms part of the vehicle’s structural foundation. This means even minor collisions can affect not only exterior panels but also battery enclosures, electrical systems, and embedded safety sensors.
- After a crash, the repair process begins with high-voltage system isolation and comprehensive diagnostic scanning to prevent electrical hazards and identify hidden faults that may not be immediately visible.
- Technicians must carefully inspect the battery enclosure for punctures, thermal damage, voltage irregularities, or structural compromise. Computerized frame measurements are used to verify alignment against manufacturer specifications.
- Aluminum structural components require specialized tools and manufacturer-approved bonding or replacement methods to preserve crash integrity and long-term durability.
- ADAS calibration is typically required after impact. Cameras, radar units, and ultrasonic sensors must be precisely realigned to ensure braking assistance, lane-keeping, and collision warning systems function properly.
- Battery damage is a major cost driver. Full battery pack replacement can range from $12,000 to $25,000 depending on the vehicle model and capacity. Severe battery compromise may lead insurers to declare a total loss.
- Certified EV repair facilities help ensure electrical safety, manufacturer compliance, warranty protection, accurate calibration, and long-term vehicle reliability.
Approximately six million police-reported crashes occur each year in the United States, which makes proper repairs essential for safety and reliability. Collision repair quality is becoming increasingly important as vehicles become more technologically complex. This extends to electric vehicles (EVs), which are built differently from internal combustion vehicles. They come with high-voltage battery packs, aluminum structures, and integrated driver-assistance systems.
After a collision, these components require careful inspection and controlled repair environments. For example, a shop such as Harry’s Auto Collision is a certified Lucid body shop, where technicians follow specialized procedures to restore structural integrity, electrical safety, and system performance for Lucid EVs. This article explores this topic in detail:
Why EV Collision Repair Is Fundamentally Different
Electric vehicles use a structural layout commonly called a skateboard platform. The high-voltage battery pack sits flat along the floor, forming part of the vehicle’s structure. This design lowers the center of gravity and improves handling, but it also means collision forces can affect the battery enclosure.
Unlike traditional steel-dominant construction, many EVs rely heavily on aluminum. Aluminum behaves differently under stress and heat, and improper repair methods can weaken its structural integrity. Technicians must use specialized tools, bonding methods, and measurement systems designed specifically for aluminum repair.
Safety systems add another layer of complexity. Electric vehicles include high-voltage disconnect mechanisms, battery monitoring systems, and multiple sensors. These systems detect damage, isolate electrical risks, and protect occupants and technicians.
Even minor collisions can trigger protective shutdowns or hidden faults. Advanced driver-assistance systems, often called ADAS, are also affected by impacts. Cameras, radar modules, and ultrasonic sensors must remain precisely aligned. A small shift in sensor position can affect braking assistance, lane-keeping, and collision warnings.
Manufacturers also publish detailed repair procedures that technicians must follow exactly. These protocols specify inspection steps, repair methods, and calibration requirements. At different repair facilities, technicians are trained to follow brand-specific procedures that address structural materials, battery safety, and software integration unique to vehicles produced by Lucid Motors.
For insurers, repair complexity affects claim decisions and cost estimates. For owners, proper repair ensures safety, performance, and long-term reliability. For technicians, the process requires specialized training and strict adherence to safety standards.
Below is a structured comparison highlighting how EV collision repair differs from internal combustion engine (ICE) vehicle repair:
| Repair Factor | Electric Vehicle (EV) | Internal Combustion Engine (ICE) Vehicle |
| Structural design | Skateboard platform with battery integrated into chassis | The engine compartment is separated from the fuel tank |
| Primary risk | High-voltage battery damage, thermal events | Fuel leaks, engine damage |
| Materials | Heavy aluminum and composite use | Primarily steel |
| Diagnostics | Software scans and battery system data | Mechanical inspection and OBD scan |
| ADAS calibration | Almost always required after impact | Required mainly in moderate/severe impacts |
| Typical repair cost | Higher | Lower relative cost |
| Complexity level | High (electrical, structural and software integration) | Moderate (primarily mechanical and structural) |
On average, EV collision repairs can range from $1,500 for minor cosmetic damage to $20,000+ for major structural or battery-related repairs. Battery replacement alone can cost between $12,000 and $25,000, depending on model and capacity, whereas comparable ICE engine replacements typically range between $4,000 and $10,000.
What to Do After a Crash
Here is a checklist of what owners should do immediately after a crash:
- Move to a safe location and power off the vehicle if possible
- Avoid touching exposed wiring or damaged battery areas
- Call emergency services if smoke, sparks, or unusual odors are present
- Inform the tow provider that the vehicle is electric
- Request towing to a certified EV repair facility
- Do not attempt to restart the vehicle if warning lights appear related to the battery or high voltage systems
The repair timeline expectation for this stage is around one to two days, depending on diagnostic complexity
The EV Repair Process Step by Step
Electric vehicles require a precise, multi-stage repair process after a collision. Here are all the steps required to address unique safety, structural, and electronic systems to restore the vehicle to its full performance.
1. Initial Safety Assessment
The first step after an EV arrives at a repair facility is ensuring electrical safety. Technicians begin by powering down the vehicle and isolating the high-voltage system. This prevents accidental electrical exposure during inspection.
Diagnostic scans are then performed to identify fault codes. These scans reveal battery issues, sensor faults, and system shutdown events triggered by the collision. Battery management systems store detailed data that helps technicians understand potential internal damage.
Visual inspection also takes place during this phase. Technicians look for coolant leaks, structural deformation, and battery enclosure damage. Even small signs can indicate deeper problems.
2. Structural and Battery Inspection
Once safety is confirmed, technicians evaluate the vehicle’s structural condition. Computerized frame measurement systems compare the vehicle’s dimensions to factory specifications. This helps determine whether they can repair the structure or if it requires replacement.
Additionally, the battery enclosure receives special attention. Technicians check for punctures, dents, or thermal damage. Any compromise to the battery casing can affect safety and performance.
Whereas aluminum repair requires precise methods. Unlike steel, aluminum cannot always be reshaped using traditional techniques. In some cases, sections must be replaced rather than repaired to maintain structural strength.
Premium electric vehicles often require repair environments designed specifically for their materials and electronics. Technicians working in these settings follow strict certification standards, use insulated tools, and access manufacturer repair systems. Facilities such as Harry’s Auto Collision Lucid body shop operate within these requirements to ensure structural accuracy, battery safety, and proper system integration throughout the repair process.
3. Component Repair and Replacement
After structural repairs are complete, technicians focus on restoring vehicle systems. Damaged components such as sensors, cameras, and wiring harnesses are replaced according to manufacturer specifications.
ADAS calibration is a critical step. Cameras and radar units must be aligned using specialized calibration equipment. This ensures safety systems function correctly and respond accurately to driving conditions.
They also inspect thermal management systems. Electric vehicles rely on cooling systems to regulate battery temperature. Technicians check coolant lines, pumps, and heat exchangers for damage or leaks.
Software diagnostics continue throughout this phase. Repairs often require system resets, firmware updates, and configuration procedures. These updates ensure all vehicle systems communicate correctly. Below is the criteria you should consider when deciding between replacing vs repairing the battery:
- Presence of cell damage or internal short circuits: Replace because damaged cells can cause unpredictable performance, fire risk, and loss of capacity. Repairing individual cells is often unsafe and not manufacturer-approved.
- Thermal runaway risk indicators: If there are signs of overheating or thermal instability, the battery can catch fire, so it’s best to replace it. Replacement ensures safety; repair is not recommended.
- Coolant contamination inside battery housing: Coolant can short electrical circuits and corrode cells, so consider replacing it in this case. Repair may not restore full integrity, so replacement prevents long-term failure
- Structural compromise of battery casing: Replace as dents or cracks weaken protection and increase crash/fire risk. Minor cosmetic dents might be repairable if cells are intact, but casing compromise generally requires full replacement.
- Manufacturer-mandated replacement thresholds: Follow the manufacturer, as some EV makers require battery replacement if certain damage criteria are met; ignoring this voids warranty and safety certification
- Cost comparison between enclosure repair and full pack replacement: Repair if safe and cost-effective. Only attempt repair if internal cells are intact, casing damage is minor, and manufacturer guidelines allow it. Otherwise, replace for safety and reliability
If the battery enclosure is dented but cells remain intact, localized repair may be approved. If internal modules show voltage irregularities or thermal damage, full pack replacement is often required.
4. Final Testing and Validation
The final stage involves confirming that the vehicle operates safely and correctly. Technicians perform road tests to evaluate handling, braking, and system performance. Diagnostic scans verify that no fault codes remain.
ADAS systems undergo validation to confirm proper calibration. They also check battery systems to ensure stable operation and safe performance. Repair facilities also document all procedures performed. This documentation provides a record for owners, insurers, and future service providers.
Common Mistakes
Common mistakes or repair pitfalls include:
- Skipping high-voltage isolation procedures
- Improper aluminum welding techniques weaken the structure
- Failure to recalibrate ADAS systems after sensor replacement
- Using non-certified replacement parts
- Overlooking minor battery casing dents that hide internal damage
- Incomplete documentation affecting warranty coverage
The repair timeline expectation for this stage is usually five to 14 days, depending on calibration complexity and software integration requirements.
Infrastructure and Workflow Behind EV Collision Repair
Electric vehicle repair facilities must be designed with safety and isolation in mind. High-voltage vehicles are often serviced in designated areas separate from conventional repair bays. These areas reduce electrical risk and prevent cross-contamination during structural repairs.
Technician certification plays a central role in repair quality. Certification programs train technicians to handle battery systems, aluminum structures, and software diagnostics. These programs also teach safe handling procedures for high-voltage components.
Parts sourcing can present challenges. EV components are often brand-specific and may not be widely available. Replacement parts must meet manufacturer specifications to ensure compatibility and safety.
This can increase repair timelines compared to traditional vehicles. Battery damage can influence insurance decisions. If battery integrity is compromised, insurers may classify the vehicle as a total loss. Battery replacement costs and safety concerns play a significant role in these evaluations.
Digital diagnostics have become essential tools. Technicians connect vehicles to manufacturer systems to retrieve data, perform calibrations, and install updates. Some calibration procedures rely on cloud-based platforms that verify proper system operation.
Coordination between repair facilities, manufacturers, and insurers ensures that repairs meet required standards. This coordination helps maintain vehicle safety and protects long-term reliability.
Repair Timeline
Typical total repair timelines look like this:
- Minor cosmetic repair: Seven to 14 days
- Moderate structural repair: Two to four weeks
- Major battery or structural replacement: Four to eight weeks (depending on part availability)
Below is a structured breakdown of EV repair stages and cost expectations:
| Repair Stage | Purpose | Estimated Time | Typical Cost Range |
| Initial Safety and Diagnostics | High-voltage isolation, system scan | One to two days | $200 to $800 |
| Structural and battery Inspection | Frame measurement, enclosure evaluation | Three to 10 days | $1,000 to $5,000 |
| Component replacement and calibration | Sensors, wiring, and ADAS alignment | Five to 14 days | $2,000 to $8,000 |
| Battery replacement (if required) | Full pack removal and installation | Two to four weeks | $12,00 to $25,000 |
| Final testing and validation | Road test, system confirmation | One to three days | $300 to $1,000 |
Owner and Shop Practices That Improve Outcomes
Prompt inspection after a collision is important, even if damage appears minor, because electric vehicles can sustain hidden battery or sensor damage that is not immediately visible. Conducting an early assessment helps identify risks before they worsen and ensures any necessary repairs are addressed promptly.
For the shop, transparency during repair builds trust and improves safety. Give detailed documentation so owners can understand what was repaired and why. It also helps future technicians maintain the vehicle correctly.
For owners, choosing certified repair facilities is critical for high-voltage vehicles. Certified technicians have the training and tools required to perform repairs safely. Improper repairs can create safety risks and reduce vehicle performance. Repair quality also affects resale value. Vehicles repaired according to manufacturer standards retain greater value and reliability.
Buyers can look for evidence of proper repair and maintenance. Battery warranty protection is another consideration. Manufacturers may require certified repair procedures to maintain warranty coverage. Repairs performed outside these standards can affect warranty eligibility.
Lastly, safety culture plays a central role in electric vehicle repair. Prioritizing proper procedures over speed or cost helps ensure long-term vehicle performance and occupant safety.
Endnote
Repairing an electric vehicle after a crash involves far more than restoring its appearance. Technicians must evaluate battery integrity, structural safety, and software functionality while following manufacturer-approved procedures.
Careful diagnostics, certified repair methods, precise calibration, clear cost expectations, realistic repair timelines, and informed owner decisions ensure the vehicle returns to safe operation. These steps help preserve performance, protect long-term reliability, and maintain the safety systems that define modern electric vehicles.
