Ford Aluminum Body Repair: How Structural Work Is Done Right

Ford switched the F-150 to an aluminum body in 2015. Here is how aluminum structural repairs are performed, and why equipment and training matter.

The Aluminum F-150 Changed Collision Repair

When Ford introduced the aluminum-body F-150 for the 2015 model year, it forced the collision industry to change. The Super Duty and Expedition followed, as did Lincoln's Navigator. Repairing these trucks correctly requires tools and methods that were rare in body shops at the time.

How Aluminum Behaves

Aluminum is lighter than steel but less forgiving. It conducts heat quickly, work-hardens when bent and can crack if over-stressed. Straightening that is routine on steel may be off-limits on aluminum.

Dedicated Equipment

  • Separate aluminum work area to prevent steel contamination
  • Dust extraction designed for aluminum particles
  • Self-piercing rivet guns and approved rivets
  • Aluminum MIG welders where welding is specified
  • Dedicated hand tools used only on aluminum

Sectioning and Replacement

Ford's repair procedures show where aluminum panels can be sectioned and how new sections are joined, often with a combination of rivets and structural adhesive. Bed sides, cab corners and rocker areas are common repair zones on trucks.

Corrosion Protection

Where aluminum meets steel, such as at frame mounts and fasteners, isolation is critical. Coated fasteners and sealers prevent galvanic corrosion over the life of the truck.

Frequently Asked Questions

Is aluminum more expensive to repair?

It can be, due to labor and equipment. But many repairs are straightforward when done by trained technicians.

Can a non-certified shop fix my aluminum F-150?

Some can, but Ford recommends facilities with the right equipment and training.

Is the F-150 frame aluminum too?

No. The body is aluminum; the frame is high-strength steel.

Learn about our aluminum repair capabilities.

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