As vehicles come equipped with an increasing number of computer modules, it's possible to make some repairs by doing a computer reflash. Performing flash reprogramming on a vehicle can improve fuel mileage, solve transmission problems, correct false trouble codes and other issues. Often these procedures are performed at dealerships, but independent repair shops also can perform reflashing, provided they have the right tools and training.
On Thursday, Donny Seyfer, operations manager at Seyfer Automotive in Wheat Ridge, Colo., presented a session on "Flash Reprogramming for the Body Shop," that focused on how to reflash computer modules on damaged vehicles. Seyfer also walked shop owners through a decision-making process to help them decide whether or not they should invest in reprogramming tools or work with outside contractors.
For collision shop owners, Seyfer explained how to use service information (such as manufacturer diagrams) to determine whether or not a module might be located in an area of the vehicle that might have been damaged during the collision.
"Once you know where that module is, then you can put a scan tool on it to see if all of the modules are reporting back," Seyfer says.
Modules that might need reflashed when they are replaced include engine management computers, transmission control modules, seat modules, security systems, and ABS system controllers.
"There are two paths to take in reflashing," Seyfer says. "You can sometimes grab the information you need off of the old module and put it on the new one, which can save a lot of time. You can pull most of the vehicle identification file off the old module, and that saves you from manually performing the reflash."
If the old module is too damaged to utilize, then repairers have to manually input the programming data into the modules. "For an American car, that might take 45 minutes," Seyfer says. "There are some European models that require eight or nine hours."
Very few collision shops currently do this type of work, so Seyfer walked the attendees through an interactive decision-making scenario to see if it would be profitable for their body shop to invest in flash reprogramming equipment.
"You start by looking at your mix of manufacturers," Seyfer says. "What do you work on the most? I feel like to really own a hardcore piece of equipment, that OE tool, you have to be able to make a pretty good case that you can make that thing pay for itself. For a lot of shops, that won't make sense right away."
That's because OE tools and devices based on the SAE 2534 standard can cost from $1,500 to more than $100,000 (in the case of a BMW tool) depending on the brand.
"You have to look at the staff you have available," Seyfer says. "Do you have anyone that isn't already operating at full tilt, because you can't put somebody on staff to do just this."
Shops also need the correct support equipment, PCs, and Internet access.
A best-case scenario, Seyfer said, would be a shop that "works on a lot of Asian and American cars, because the tools are less expensive. You also have to be able to do a certain amount of this work on a regular basis. Just turning off the check engine light would make it hard to rationalize an $8,000 tool," he says. "If you can do module replacements or diagnose lighting problems, that makes more sense."
In terms of insurance claims, Seyfer said charging a flat rate for module replacement seems to work best with most insurance carriers. "If there's diagnosis involved, we do that at an hourly mechanical rate," he says.
Beyond just the cost of the equipment, there also are technical challenges to reflashing. "There are a few modules that if you don't do this right the first time, you have to replace the module," Seyfer says. "If the battery goes low or dies during the process, you can destroy the module, so you have to have battery support during the reprogramming. These can be expensive mistakes if you haven't done your homework on the front end."
