to successfully export/import the car, the process is like this:
initiate the export in the AES direct export system, which either the exporter does themselves by completing a certification quiz for the system or finding a shipper to initiate it for you. The border will not accept the paperwork for your export without the ITN# that is created by this system. it is mandatory as of Oct 2. The exporter will need to apply for a tax ID# from the IRS. This is what the system uses to identify the exporter instead of SS#. Even if a shipper is used to initiate, the exporter may still be required to get a # for themselves, it can not be confirmed shippers will use their own number. It is easy to get a # by calling the IRS or applying online.
Drop off the ITN# and Original title to the border you will be crossing at least 72 hours prior to export. To find out if the border accepts a fax copy of everything you will have to call the border office to verify. for some, they will only accept original copies.
day of export: go to the export office at your border of choice, they will stamp your tilte and give it back.
to import:
after export, you need to import the car on the canadian side, so you will need to bring the paperwork from the US to the canadian immigration office. at this time, the modifications don't need to be made on your car. at this point, the import is being initiated, and border control will give you the Form 1 needed in order to get inspected.
Once you finish at the border, you have to confim with RIV they received a copy of the Form 1 from the border office because even if it was sent, it doesn't mean it was entered into their system (learned the hard way). you will also need to send the recall clearance to RIV and pay the fee (which you may not be allowed to do at the border - i was instructed to do it online) before they will release your inspection report (form 2)- which needs to be presented to the inspection service center.
once your inspection report is released, you can make an appointment with one of the authorized inspection service centers in your area (probably a canadian tire - the RIV site provides a list), where they will do the inspection for emissions, any provencial safety, and the RIV inspection. before they complete the RIV inspection, they will check for and do the modifications that are necessary. While it may be cheaper to do it in the states, it's far easier just to wait until the process is initiated before doing anything. It cost $150 to get my DTL package installed at time of inspection at canadian tire.
after inspection, the service center will fax Form 2 back to RIV to show you passed the inspection. Supposedly at this point you are clear to register the car. I haven't gotten this far yet, and will call RIV this week to confirm the import has been finalized. there are a lot of little steps that are needed and surprisingly it's not that hefty of a price tag. the RIV is pretty easy to work with, and they are very helpful over the phone. the biggest headache is figuring out how to get the export initiated into the AES direct system on the US side.