I should have known my initial post was too long, and with modern attention spans it would not even be read adequately.
I've read your entire post and understand your frustration in the matter but you are missing the point I am making. While your logic makes sense from a "mathematical" perspective, it will not work from a business perspective.
You admitted to them that:
- The part was never installed.
- The box was damaged which may have been taken as "the part has also been damaged from user error or other circumstances".
Both of these options open grounds for them to deny the claim if they choose to.
FCP has started cracking down on warranty abuse, as in people who buy parts to see if they fit etc.. and then return them or breaking them during install etc.. Unfortunately for you, the changes have been happening as of 11/1/22 and FCP is tightening what they allow and don't allow etc.
Also, for lifetime warranty replacements, you do not need to send back the original box. It can be shipped however way it needs to be. I often ship back in the original box or in the box the new part comes in as I don't need more waste accumulating here than needed.
So my original point still stands, if it was originally filed as a lifetime warranty, there would have likely been no investigation and it would have gone smooth. I'm not trying to place blame or say who is right or wrong, but this is a case of jumping the gun and shooting yourself in the foot.
At the end of the day, they are a business, not a person or a friend. They operate to make a profit. As a result, you as a customer also need to be aware of what to do and not to do to save your wallet.
Give them a call and try to talk through the situation and see what they may say.
As for if the parts are being reused or rebuilt, I have two things to say. First, I would hope they are being recycled or being rebuilt. Parts are already scarce as is and we have enough waste on this planet as is. Those parts can be sold as "rebuilt" units but not new. I see nothing wrong there. Second, this isn't new. They have explained the process of what they do with old oil etc.. Again, from a business perspective, if I could make money rebuilding/selling cores etc.. why wouldn't I?
Here is a few interesting points being made in the BMW forums: FCP Euro Lifetime Replacement Guarantee Update - NA M3 Forums