Author: Michael Crandell and Joe Baker

Auto Collision Repair and Refinishing is a comprehensive text aligned to the latest ASE Education Foundation Collision Repair and Refinishing Task List, developed to prepare students for entry-level employment in the collision repair industry. It covers new materials, techniques, and equipment used in collision repair, with a focus on safe shop practice, PPE, and adherence to Original Equipment Manufacturers (OEM) procedures. This edition includes a new feature, Focus on Aluminum, which highlights the importance of keeping aluminum repair areas and tools free from contamination by materials and tools used on steel and plastic parts. It emphasizes safe practices to minimize the dangers of failing to keep aluminum repair areas, tools, and equipment separate. The Auto Collision Repair and Refinishing Shop Manual provides 126 hands-on job sheets that correspond to one or more ASE Education Foundation Tasks. Digital users have access to eBook content, online shop manual content, online workbook content, Collision Repair and Refinishing Virtual Toolbox, Multimeter Simulations, interactive activities, and MotoVisuals from Advance Auto Parts.

Table of Contents

Abbreviated Contents

Auto Collision Repair and Refinishing 4e, Online Textbook

• Auto Collision Repair and Refinishing
• Copyright © 2027 by The Goodheart-Willcox Company, Inc.
• Preface
• About the Authors
• Reviewers
• Acknowledgments
• New to This Edition
• ASE Connections
• Features of the Textbook
• • Chapter Opening Materials
  • Additional Features
  • Illustrations
  • End-of-Chapter Content
• Tools For Student And Instructor Success
• • Student Tools
  • Instructor Tools
• Brief Contents
• Contents
• Feature Contents
• • Focus on Aluminum
  • Working Green
• Section 1 Introduction to Collision Repair
• Chapter 1 Introduction to Collision Repair
• • Chapter 1 Learning Outcomes
  • Chapter 1 Technical Terms
  • Chapter 1 Introduction
  • 1.1 The Repair Process
  • 1.2 Insurance Claims
  • 1.3 Ordering Parts
  • 1.4 Pre-Scanning and Blueprinting
  • 1.5 Repair and Refinishing
  • 1.6 Body Shop Types
  • 1.7 Educational Opportunities
  • Chapter 1 Review and Assessment
• Chapter 2 Employability Skills and Careers in the Auto Collision Industry
• • Chapter 2 Learning Outcomes
  • Chapter 2 Technical Terms
  • Chapter 2 Introduction
  • 2.1 Exploring Job Opportunities
  • 2.2 Working as a Collision Repair Technician
  • 2.3 Job Hunting
  • 2.4 Succeeding in the Workplace
  • 2.5 Professional Education
  • 2.6 Careers in the Collision Repair Facility
  • 2.7 Careers Outside of a Collision Repair Facility
  • Chapter 2 Review and Assessment
• Chapter 3 Safety
• • Chapter 3 Learning Outcomes
  • Chapter 3 Technical Terms
  • Chapter 3 Introduction
  • 3.1 Collision Repair Shop Hazards
  • 3.2 Hazardous Wastes
  • 3.3 Safe Work Practices
  • 3.4 Implementing Safety Protocols
  • 3.5 Environmental Regulations
  • 3.6 Personal Protective Equipment
  • Chapter 3 Review and Assessment
• Chapter 4 Vehicle Construction
• • Chapter 4 Learning Outcomes
  • Chapter 4 Technical Terms
  • Chapter 4 Introduction
  • 4.1 Vehicle Classifications
  • 4.2 Material Types
  • 4.3 Vehicle Parts: Outer Body Assemblies
  • 4.4 Vehicle Parts: Inner Body Assemblies
  • 4.5 Vehicle Production
  • 4.6 Vehicle Safety Rating
  • Chapter 4 Review and Assessment
• Chapter 5 Tools, Equipment, and Repair Procedures
• • Chapter 5 Learning Outcomes
  • Chapter 5 Technical Terms
  • Chapter 5 Introduction
  • 5.1 Tool Grades
  • 5.2 Hand Tools
  • 5.3 Power Tools
  • 5.4 Tool Storage
  • 5.5 Shop Equipment
  • 5.6 Repair Procedures
  • Chapter 5 Review and Assessment
• Chapter 6 Fasteners
• • Chapter 6 Learning Outcomes
  • Chapter 6 Technical Terms
  • Chapter 6 Introduction
  • 6.1 Galvanic Corrosion
  • 6.2 Threaded Fasteners
  • 6.3 Threaded Fastener Service
  • 6.4 Nonthreaded Fasteners
  • 6.5 Hybrid Bonding
  • 6.6 Plastic Fasteners
  • Chapter 6 Review and Assessment
• Section 2 Nonstructural Repairs
• Chapter 7 Metal Straightening Tools, Equipment, and Materials
• • Chapter 7 Learning Outcomes
  • Chapter 7 Technical Terms
  • Chapter 7 Introduction
  • 7.1 Body Repair Hand Tools
  • 7.2 Panel Repair Power Tools
  • 7.3 Nonstructural Repair Materials
  • 7.4 Sandpaper
  • Chapter 7 Review and Assessment
• Chapter 8 Metal Straightening
• • Chapter 8 Learning Outcomes
  • Chapter 8 Technical Terms
  • Chapter 8 Introduction
  • 8.1 Fundamentals of Damage Repair
  • 8.2 Damage Types
  • 8.3 Damage Identification
  • 8.4 Planning the Repair
  • 8.5 Roughing Out
  • 8.6 Roughing Out Specific Types of Damage
  • 8.7 Finishing
  • 8.8 Corrosion Protection
  • Chapter 8 Review and Assessment
• Chapter 9 Bolt-On Part Replacement
• • Chapter 9 Learning Outcomes
  • Chapter 9 Technical Terms
  • Chapter 9 Introduction
  • 9.1 Sources
  • 9.2 Bolted Part Replacement Steps
  • 9.3 Removing Damaged Fasteners
  • 9.4 Replacing Specific Bolted Parts
  • Chapter 9 Review and Assessment
• Chapter 10 Welding and Cutting
• • Chapter 10 Learning Outcomes
  • Chapter 10 Technical Terms
  • Chapter 10 Introduction
  • 10.1 Welding Safety
  • 10.2 Welding Fundamentals
  • 10.3 MIG Welding
  • 10.4 Testing Welds
  • 10.5 MIG Brazing
  • 10.6 Flux-Cored Arc Welding
  • 10.7 Resistance Welding
  • 10.8 Using an Oxyacetylene Torch
  • 10.9 Heating Steel Parts
  • 10.10 Cutting Metal Parts
  • Chapter 10 Review and Assessment
• Chapter 11 Welded and Bonded Exterior Panel Replacement
• • Chapter 11 Learning Outcomes
  • Chapter 11 Technical Terms
  • Chapter 11 Introduction
  • 11.1 Reading the Estimate
  • 11.2 Analyzing the Damage
  • 11.3 Planning the Repair
  • 11.4 Accessing the Damage
  • 11.5 Removing the Damaged Panel
  • 11.6 Test-Fitting the Replacement Panel
  • 11.7 Preparing Panels
  • 11.8 Replacing Exterior Panels
  • Chapter 11 Review and Assessment
• Chapter 12 Plastic Repair
• • Chapter 12 Learning Outcomes
  • Chapter 12 Technical Terms
  • Chapter 12 Introduction
  • 12.1 Classifying Plastics
  • 12.2 Tools and Materials
  • 12.3 Plastic Repair Steps
  • 12.4 Repairing Specific Types of Damage
  • Chapter 12 Review and Assessment
• Chapter 13 Glass
• • Chapter 13 Learning Outcomes
  • Chapter 13 Technical Terms
  • Chapter 13 Introduction
  • 13.1 Types of Glass
  • 13.2 Movable and Fixed Glass
  • 13.3 Glass Removal and Installation Tools
  • 13.4 Glass Replacement Materials
  • 13.5 Glass Service
  • 13.6 Leak Checks
  • Chapter 13 Overview and Assessment
• Section 3 Structural Repairs
• Chapter 14 Unibody/Frame Straightening Equipment
• • Chapter 14 Learning Outcomes
  • Chapter 14 Technical Terms
  • Chapter 14 Introduction
  • 14.1 Pulling Tools Equipment
  • 14.2 Pulls
  • 14.3 Frame Machine Types
  • Chapter 14 Review and Assessment
• Chapter 15 Measurements
• • Chapter 15 Learning Outcomes
  • Chapter 15 Technical Terms
  • Chapter 15 Introduction
  • 15.1 Measuring Tools
  • 15.2 Linear Measurements
  • 15.3 One-Dimensional Measurements
  • 15.4 Two-Dimensional Measurements
  • 15.5 Three-Dimensional Measurements
  • 15.6 Damage Diagram
  • Chapter 15 Review and Assessment
• Chapter 16 Unibody Straightening
• • Chapter 16 Learning Outcomes
  • Chapter 16 Technical Terms
  • Chapter 16 Introduction
  • 16.1 Basic Unibody Straightening Operations
  • 16.2 Straightening Damage
  • 16.3 Straightening Specific Types of Unibody Damage
  • Chapter 16 Review and Assessment
• Chapter 17 Full-Frame Repair
• • Chapter 17 Learning Outcomes
  • Chapter 17 Technical Terms
  • Chapter 17 Introduction
  • 17.1 Basic Frame Straightening Operations
  • 17.2 Damage Analysis
  • 17.3 Frame Pulls, Pushes, and Stress Relief Techniques
  • 17.4 Repairing Specific Types of Frame Damage
  • Chapter 17 Review and Assessment
• Chapter 18 Structural Component Replacement
• • Chapter 18 Learning Outcomes
  • Chapter 18 Technical Terms
  • Chapter 18 Introduction
  • 18.1 Structural Panel Replacement Procedures
  • 18.2 Replacement Part Sources
  • 18.3 Replacing Structural Unibody Components
  • 18.4 Replacing Full-Frame Components
  • Chapter 18 Review and Assessment
• Section 4 Mechanical and Electrical Repairs
• Chapter 19 Steering and Suspension
• • Chapter 19 Learning Outcomes
  • Chapter 19 Technical Terms
  • Chapter 19 Introduction
  • 19.1 Steering System Fundamentals
  • 19.2 Steering System Types and Key Components
  • 19.3 Suspension System Fundamentals
  • 19.4 Suspension System Types and Key Components
  • 19.5 Diagnosing Steering, Suspension, and Wheel Assembly Damage
  • 19.6 Steering and Suspension System Replacement Steps
  • 19.7 Wheel, Hub, and Tire Service
  • 19.8 Alignment
  • Chapter 19 Review and Assessment
• Chapter 20 Electric Vehicles
• • Chapter 20 Learning Outcomes
  • Chapter 20 Technical Terms
  • Chapter 20 Introduction
  • 20.1 xEV Personal Protective Equipment
  • 20.2 xEV Safety
  • 20.3 Dedicated Insulated xEV Tools
  • 20.4 Types of xEVs
  • 20.5 Thermal Management
  • 20.6 Charging Options and Procedures
  • 20.7 Handling Incoming Damaged xEVs
  • 20.8 xEV-Specific Tasks Performed in a Body Shop
  • Chapter 20 Review and Assessment
• Chapter 21 Electrical System
• • Chapter 21 Learning Outcomes
  • Chapter 21 Technical Terms
  • Chapter 21 Introduction
  • 21.1 Basic Electricity
  • 21.2 Basic Electrical Parts
  • 21.3 Modern Electrical Systems
  • 21.4 Basic Electrical Tests and Service Operations
  • 21.5 Electrical System Service
  • Chapter 21 Review and Assessment
• Chapter 22 Brakes
• • Chapter 22 Learning Outcomes
  • Chapter 22 Technical Terms
  • Chapter 22 Introduction
  • 22.1 Brake System Principles
  • 22.2 Brake System Components and Operation
  • 22.3 Repairing the Brake System
  • Chapter 22 Review and Assessment
• Chapter 23 Cooling, Heating, and Air Conditioning Systems
• • Chapter 23 Learning Outcomes
  • Chapter 23 Technical Terms
  • Chapter 23 Introduction
  • 23.1 Cooling System
  • 23.2 Heating System
  • 23.3 Air Conditioning System
  • Chapter 23 Review and Assessment
• Chapter 24 Power Train
• • Chapter 24 Learning Outcomes
  • Chapter 24 Technical Terms
  • Chapter 24 Introduction
  • 24.1 Power Sources and Drivetrain Configurations
  • 24.2 Engine Components
  • 24.3 Drivetrain Components
  • 24.4 Power Train Service and Repair
  • Chapter 24 Review and Assessment
• Chapter 25 Safety and Restraint Systems
• • Chapter 25 Learning Outcomes
  • Chapter 25 Technical Terms
  • Chapter 25 Introduction
  • 25.1 Safety Restraint Systems
  • 25.2 Servicing Airbags
  • 25.3 Active Safety Systems
  • 25.4 Structural Safety Features
  • Chapter 25 Review and Assessment
• Section 5 Refinishing
• Chapter 26 Refinishing Tools and Equipment
• • Chapter 26 Learning Outcomes
  • Chapter 26 Technical Terms
  • Chapter 26 Introduction
  • 26.1 Hand Tools
  • 26.2 Power Tools
  • 26.3 Refinishing Equipment
  • 26.4 Additional Refinishing Equipment
  • Chapter 26 Review and Assessment
• Chapter 27 Refinishing Materials
• • Chapter 27 Learning Outcomes
  • Chapter 27 Technical Terms
  • Chapter 27 Introduction
  • 27.1 Paint Classifications
  • 27.2 Paint Components
  • 27.3 Topcoats
  • 27.4 Specialty Topcoats
  • 27.5 Undercoats
  • 27.6 Abrasives
  • 27.7 Masking
  • 27.8 Mixing and Straining Supplies
  • 27.9 Buffing Materials
  • 27.10 Additional Refinishing Materials
  • Chapter 27 Review and Assessment
• Chapter 28 Paint Mixing and Reducing
• • Chapter 28 Learning Outcomes
  • Chapter 28 Technical Terms
  • Chapter 28 Introduction
  • 28.1 Paint Code Identification
  • 28.2 Paint Sources
  • 28.3 Paint-Mixing Equipment
  • 28.4 Paint Formulas
  • 28.5 Paint Reduction
  • Chapter 28 Review and Assessment
• Chapter 29 Spray Technique
• • Chapter 29 Learning Outcomes
  • Chapter 29 Technical Terms
  • Chapter 29 Introduction
  • 29.1 Paint Properties
  • 29.2 Spray Gun Setup
  • 29.3 Basic Painting Skills
  • 29.4 Spray Gun Handling
  • 29.5 Application Techniques
  • 29.6 Spraying Body Panels
  • 29.7 Contamination Control
  • 29.8 Spray Gun Cleaning
  • Chapter 29 Review and Assessment
• Chapter 30 Surface Preparation
• • Chapter 30 Learning Outcomes
  • Chapter 30 Technical Terms
  • Chapter 30 Introduction
  • 30.1 Surface Preparation Standards
  • 30.2 Prewash and Surface Cleaning
  • 30.3 Panel Assessment
  • 30.4 Planning the Repair
  • 30.5 Paint Removal
  • 30.6 Surfacer Application
  • 30.7 Preparation for Topcoats
  • 30.8 Surface Preparation for Specific Types of Damage
  • Chapter 30 Review and Assessment
• Chapter 31 Color Matching
• • Chapter 31 Learning Outcomes
  • Chapter 31 Technical Terms
  • Chapter 31 Introduction
  • 31.1 What Is Color?
  • 31.2 Lighting
  • 31.3 Color Comparison
  • 31.4 Altering Color
  • Chapter 31 Review and Assessment
• Chapter 32 Paint Application
• • Chapter 32 Learning Outcomes
  • Chapter 32 Technical Terms
  • Chapter 32 Introduction
  • 32.1 Contamination Sources
  • 32.2 Applying Paint
  • 32.3 Blending Strategies
  • 32.4 Final Curing and Unmasking
  • 32.5 Troubleshooting
  • Chapter 32 Review and Assessment
• Chapter 33 Specialty Painting
• • Chapter 33 Learning Outcomes
  • Chapter 33 Technical Terms
  • Chapter 33 Introduction
  • 33.1 Understanding Automotive Plastics
  • 33.2 Preparing and Refinishing Plastic Parts
  • 33.3 Wraps and Decals
  • 33.4 Custom Painting
  • Chapter 33 Review and Assessment
• Chapter 34 Detailing
• • Chapter 34 Learning Outcomes
  • Chapter 34 Technical Terms
  • Chapter 34 Introduction
  • 34.1 Paintless Dent Repair
  • 34.2 Sanding
  • 34.3 Buffing and Polishing
  • 34.4 Removing Surface Imperfections
  • 34.5 Cleaning and Retaping Moldings
  • 34.6 Interior Cleaning
  • 34.7 Exterior Cleaning
  • Chapter 34 Review and Assessment
• Section 6 Estimating and Certification
• Chapter 35 Estimating
• • Chapter 35 Learning Outcomes
  • Chapter 35 Technical Terms
  • Chapter 35 Introduction
  • 35.1 Role of the Estimator
  • 35.2 Blueprinting
  • 35.3 Parts
  • 35.4 Labor Rates and Allowances
  • 35.5 Profit Margins and Prices
  • 35.6 Additional Charges
  • Chapter 35 Review and Assessment
• Chapter 36 ASE Certification
• • Chapter 36 Learning Outcomes
  • Chapter 36 Technical Terms
  • Chapter 36 Introduction
  • 36.1 What Is ASE Certification?
  • 36.2 Why Should You Become ASE Certified?
  • 36.3 How Do I Become ASE Certified?
  • 36.4 ASE Education Foundation
  • 36.5 Specialty ASE Certifications
  • 36.6 What Are the ASE Tests Like?
  • 36.7 Collision Repair Shop Certifications
  • Chapter 36 Review and Assessment
• Glossary
• Index