Bosal Cat Converter EPIC FAIL! pics

4360 Views 20 Replies 7 Participants Last post by MeMySelfundIch, Dec 15, 2013

magna steyr 210.282

Discussion Starter · Sep 24, 2012 (Edited)

3

Bosal Cat Converter EPIC FAIL! pics Updated.. Returned pics

Built on a monday!

I ordered the drivers and passenger cat assemblies online for around 800 bucks shipped. The driver side fit fine and looked OK.

The passenger side was welded wrong. It was close when looking at the Merc part and the Bosal on the ground. When we got it in. The flange that goes to the exhaust manifold on the motor was off by about 20 degrees creating an exhaust leak. It would not seal up. The only way we could get it to seal 90 percent of the way was to not use the transmission bracket. This is unacceptable.

SO anyway, if you have the money to buy the oem parts. I bet they fit a whole lot better!

I will see what the guys I ordered from will now do. Hopefully just ship me out a new one and I can return the old one with a return slip.

No wagon for a while. I don't want to put the old ones back in. Just let it sit until I get a good one.

Attached are some photos of the cats. Notice how far off it is on the tranny bracket and how much space there is above the cat! More than a full snus can of clearance!

Needless to say, my friend who works on cars all day long was not stoked with the product. We spent 3 hours dicking around trying to make it work. He's a Mercedes Master Tech who works on this stuff everyday so it went in easy. The trouble started when we fired it up. It was ORC off and sounded like a race car.

Oh well, good things come to those who wait?

What did you use for a direct fit replacement?

I'll let you know what happens with the return.

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Check Codes

· #2 · Sep 24, 2012

I've never heard anything either way about Bosal cats, but this is surprising that someone's jig would be that far out of alignment.

You might also check with the company to see if they will reimburse you for modifying it (and still warranty the unit); cut, turn to angle, reweld. That would be faster for you and cheaper for them than shipping both units back and forth, and it won't hurt the unit so long as you don't cut into the cat or the flex coupling.

Good luck.

magna steyr 210.282

Discussion Starter · #3 · Sep 24, 2012

Check Codes said:
I've never heard anything either way about Bosal cats, but this is surprising that someone's jig would be that far out of alignment.

You might also check with the company to see if they will reimburse you for modifying it (and still warranty the unit); cut, turn to angle, reweld. That would be faster for you and cheaper for them than shipping both units back and forth, and it won't hurt the unit so long as you don't cut into the cat or the flex coupling.

Good luck.

After looking at it closer and really comparing the two, there are several errors throughout the assembly. The welds and materials look great but the bend is slightly off at about 20 degrees and short 3.25mm. The only way I could do it would be to cut it off at the pre cat, then bend it, weld it back on and then possibly still have to cut off and reassemble the tranny bracket.

I'd rather get the part done right. They will have to eat the shipping on all ends. My welding skills are not like the guys that do this 8 hours a day 5 days a week. Too many errors for me to correct without making it look like a fankenstein assembly.

This car is only used for road tours with the family and stress relief (fishing) for me. It can sit in the garage for a little while. I could just put the merc. cat back on the right side but I'm wondering about flow specs being different between the two. Probably not a big deal.

Either way, there is something to be said about Merc parts... They work and fit like a glove.

Would I go OEM if I could do it over again? Probably not at at the prices I have found. Sure wish the previous owner would have caught this under warranty. It would have been honorably discharged from the vehicle!

at only 80K, I think it's pretty sad that a cat fails like that. The passenger side front cat was loose as a goose.

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Check Codes

· #4 · Sep 24, 2012

magna steyr 210.282 said:
After looking at it closer and really comparing the two, there are several errors throughout the assembly. The welds and materials look great but the bend is slightly off at about 20 degrees and short 3.25mm. The only way I could do it would be to cut it off at the pre cat, then bend it, weld it back on and then possibly still have to cut off and reassemble the tranny bracket.

I'd rather get the part done right. They will have to eat the shipping on all ends. My welding skills are not like the guys that do this 8 hours a day 5 days a week. Too many errors for me to correct without making it look like a fankenstein assembly.

This car is only used for road tours with the family and stress relief (fishing) for me. It can sit in the garage for a little while. I could just put the merc. cat back on the right side but I'm wondering about flow specs being different between the two. Probably not a big deal.

Either way, there is something to be said about Merc parts... They work and fit like a glove.

Would I go OEM if I could do it over again? Probably not at at the prices I have found. Sure wish the previous owner would have caught this under warranty. It would have been honorably discharged from the vehicle!

at only 80K, I think it's pretty sad that a cat fails like that. The passenger side front cat was loose as a goose.

I didn't mean to suggest that *you* would be the one doing the welding. Rather that you could make the suggestion to the company, then take the old and new one down to an exhaust shop (or other decent welder) to have them do the refit work. OTOH, if it is off by that much (including the length) then it sounds as though perhaps it's a mismarked part and not actually made as a direct fit replacement for your wagon.

I tend to agree with you about MB parts, they do fit properly, although the OE cats were just crap, so I can't agree that they always "work" properly.

Look on the bright side: at least you're not in CA, where we have no choice but to buy the OE cats through the dealer network...and MB dealers gouge more than most.

Do follow up and let us know what they end up doing for you, as well as the vendor through whom you bought the parts. Problems do arise, but the real issue is how they resolve those problems. Those that resolve them satisfactorily deserve some public kudos, so others will know they are a trustworthy source, and those that do not deserve some public shaming so that others can avoid them.

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magna steyr 210.282

Discussion Starter · #5 · Sep 24, 2012

I'll keep you informed on the issues.

I purchased these cats from Partsgeek.com So far I have had good communications with them and even had a few emails to confirm that it would indeed fit my car after giving them my info and VIN number.

I shot them an email today and it usually takes them one business day to respond. They do have a lot of crappy feedback, but I take that with a grain of salt. Lots of people complain when they don't get stuff instantly. I live in the sticks as far as parts go so I can expect a little wait time. I figure things go bad on the assembly line every once in a while.

It sure looked close on the ground side by side. Really close.

Bosal told me to contact the seller and have it replaced. Hopefully with no problems.

The part number is Bosal 099-1532 for the passenger side.

Check Codes

· #6 · Sep 24, 2012

magna steyr 210.282 said:
I'll keep you informed on the issues.

I purchased these cats from Partsgeek.com So far I have had good communications with them and even had a few emails to confirm that it would indeed fit my car after giving them my info and VIN number.

Bosal told me to contact the seller and have it replaced. Hopefully with no problems.

The part number is Bosal 099-1532 for the passenger side.

That's not exactly what I said. While that may be the correct part number, it is entirely possible that the part you received, while marked with that number, is not actually that part. Such things do happen.

I had a beast of a time with a Parts Geek return, it was a motor mount for a Camry. It was similar to your issue, the part they sent was not correct, though it was in a box with the correct part number. I argued with them for quite a while before they agreed to take the part back, and while they issued a full refund, I ended up having to pay return shipping. I'd have disputed the entire thing through the credit card company, but too much time had passed for that to work (I think part of why they strung me along was to let it pass that deadline).

magna steyr 210.282

Discussion Starter · #7 · Sep 24, 2012

I understand what you said. I was just letting you know that I did order the one that bosal suggests. I'd expect them to make a mistake every once in a while.

Hopefully they have ironed out the problems and will just replace it. After the emails I sent them, they should pay for the shipping back on the exhaust since it was an error by Bosal or the seller, they also make occasional mistakes!

What is the length of time you have to dispute your credit card orders? I noticed you have 30 days with partsgeek to notify them of a problem.

Thanks for your insight. I will keep you posted!

Check Codes

· #8 · Sep 24, 2012

As I was going to replace the motor and transmission mounts in my mom's car, who lives in another state, I ordered the parts and had them shipped well in advance to be sure they'd be there once I was. So it was also after their thirty-days nonsense, but now that you mention it, that was one of their other objections to the return. Obviously I wasn't particularly happy and since there are lots of other sellers online, I no longer use Parts Geek.

magna steyr 210.282

Discussion Starter · #9 · Sep 26, 2012

Well, every time you contact partsgeek.com it takes them 3 days to respond by email. I can not find a phone number. They sent me an email with a return authorization number with a bunch of stipulations.

The flange had to be bent a little at the manifold for it to close down. This happens to darn near every assembly I have put on my other vehicles and we also stripped off all the stickers from the unit. Therefore it is used and will not be able to be resold.

The part is defective and their stipulations don't account for this. We disputed the charges and will return the part as soon as I get another one from a different distributor and install it.

The next one I order will be coming from Amazon. They have never had any problems with returns and have taken really good care of us.

She sits in the garage since I really dont want to run it with a leak and don't want to run one Bosal and one Mercedes.

Good things come to those who wait. We have a 2K+ road tour coming up in November so I have plenty of time to get ready.

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magna steyr 210.282

Discussion Starter · #10 · Sep 28, 2012

UPDATED

I got a RA number from partsgeek.com (later than 72 hrs) and have already disputed the claim because of the lack of communication.

Next step is to order the BOSAL 099-1532 which I was assured would fit the 4matic wagon by the BOSAL guy in CO.

I plan to buy it from FCP euro. Anybody have any experience with them? looks like they are squared away and on the level.

Thanks for any insight!

Check Codes

· #11 · Sep 28, 2012

magna steyr 210.282 said:
UPDATED

I got a RA number from partsgeek.com (later than 72 hrs) and have already disputed the claim because of the lack of communication.

Next step is to order the BOSAL 099-1532 which I was assured would fit the 4matic wagon by the BOSAL guy in CO.

I plan to buy it from FCP euro. Anybody have any experience with them? looks like they are squared away and on the level.

Thanks for any insight!

I have not ordered from them previously. But I will say this, I would call them to order it and be very clear about what has happened and why and see what their policy will be if you have another one that does not fit. Best to know up front, at least IMHO.

Sorry to hear the geek folks are not being kind.

Good luck.

magna steyr 210.282

Discussion Starter · #12 · Sep 29, 2012

It's not that they haven't been kind. It appears that they are a cut throat parts business that drop ships items. It takes up to 30 days to get a refund on defective items. We will see if they get sketchy on the refund. All my communications have been documented online. Even the Bosal guys said that defects happen and that it could have slipped in the jig. Unfortunately for me, they have to get the item back and then deal with bosal. One of their techs will have to confirm that it is out of spec. I'm covered on the install since my friend did it and is a professional. I was basically just his helper and learned a lot about the procedure. First time I have ever heard him swear and throw his snap on tools. I just hope that things get squared away without too much hassle. I believe they want to remain competitive and will resolve this dispute because of the defective part.

I will make sure to talk to them about the situation and their policy on returns at FCP Euro, They have lots of users here that have commented on using them. They have really good reviews online from multiple sources and their shop is on this forum. I trust that the first one was just an error and the next one will be smooth as silk.

Thanks for the luck! Need it!

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magna steyr 210.282

Discussion Starter · #13 · Oct 2, 2012

Just updating things, I talked to Dave at FCPeuro. I was impressed with their customer service department and sales. He helped me confirm, again, that the part number was correct and that if it was defective there would be no problem returning it. He helped me get the oem hydraulic fluid I needed and even found the lenses for my fog lights that have been eaten up by road rash over the years. He quoted me a really good price on the rear self leveling struts as well..

I'm happy to have found this company and think things will go really well based on their professionalism and ability to find exactly what I need within seconds.

Should be putting them in sometime next week end. I'll let you know how it all turns out!

Thanks to the other guys on here that have shared their positive experiences with FCPeuro. They rock and you rock!

dykaar

· #14 · Oct 3, 2012

Cats and FCP

I've dealt with FCP for years. When there's a problem they make it right. WRT cats, I just had a generic cat welded in when the OEM one clogged. ~$200.

I did an exhaust on an Audi Fox in grad school. In Winter. In an open carport. I promised myself never again.

magna steyr 210.282

Discussion Starter · #15 · Oct 12, 2012 (Edited)

5

Ok, another update. I put the mercedes cat back in the passenger side since it was still good. The backpressure was actively tested and everything checks out good with one bosal on the L and merc on the R.

I sent the defective passenger side bosal cat back to parts geek. It cost me $71.00 to ship it with 400 dollars insurance and tracking.

The package came from Bosal directly in Indiana so PartsGeek is a drop ship company with no inventory. The bosal guy in colorado told me to contact them if partsgeek screws around with the refund. I have read stories that they will also charge me a 15% restocking fee. They better not with a defective product. I highly doubt they will offer to pay for the shipping back to them.

Here are some photos of the original and the bosal side by side lined up as close as possible on the ground. You can see the flange angle is off, the transmission bracket mount was the common point of alignment when I took the shot. The pipe is also ORC short at the end. You can see where the exhaust leak was in the photos.

Their return policy is really sketchy. This is a defective part and the only way to know that is to use it. They both looked really close to each other at first. Installed and only then found out about the leak. Tried to correct with the bracket and a few other things.... No dice.

I will let you know how long it takes for a refund. I will dispute it again if the part is charged a restock fee.

Not really Parts Geek's fault. It was Bosals. Maybe I should ask them to be compensated for the shipping? I have bosals on two other cars here..... Not too stoked about this...

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C_R

· #16 · Oct 12, 2012

Make sure that you are not out 1 penny. Dispute the charge with your credit card and ask them to hold the payment. Even if it is not partsgeek's fault (in your opinion) still do this. Maybe it will teach partsgeek a lesson to only do business with companies that put out a good product. Make partsgeek recover the shipping from bosal. Only after all is resolves, authorize your credit card company to release the funds related to the 1 part and shipping for the good part and minus your shipping back. Doesn't matter whose fault it was. You bought it from partsgeek. THEY are responsible.

magna steyr 210.282

Discussion Starter · #17 · Oct 12, 2012

Cancer_Researcher said:
Make sure that you are not out 1 penny. Dispute the charge with your credit card and ask them to hold the payment. Even if it is not partsgeek's fault (in your opinion) still do this. Maybe it will teach partsgeek a lesson to only do business with companies that put out a good product. Make partsgeek recover the shipping from bosal. Only after all is resolves, authorize your credit card company to release the funds related to the 1 part and shipping for the good part and minus your shipping back. Doesn't matter whose fault it was. You bought it from partsgeek. THEY are responsible.

I will do that! Thanks for the info. I disputed it immediately since I read their feedback online. My bad for not doing the research. Their own feedback looks rigged. The BBB gives them an F and other places give them really, really poor ratings as well. I will dispute it again with proof that it was shipped back. I did everything by the book and followed their directions. I will request that they have bosal refund the shipping cost.

Do you think I should contact bosal directly? The guys name and number from indiana where it was shipped from bosal was on the box.

Thanks again..

C_R

· #18 · Oct 12, 2012

magna steyr 210.282 said:
I will do that! Thanks for the info. I disputed it immediately since I read their feedback online. My bad for not doing the research. Their own feedback looks rigged. The BBB gives them an F and other places give them really, really poor ratings as well. I will dispute it again with proof that it was shipped back. I did everything by the book and followed their directions. I will request that they have bosal refund the shipping cost.

Do you think I should contact bosal directly? The guys name and number from indiana where it was shipped from bosal was on the box.

Thanks again..

No, you don't need to contact Bosal. You have no business with Bosal. Your only business is with partsgeek. Let partsgeek recover the shipping costs from Bosal on their own. When partsgeek gets in touch with you regarding the dispute and them haven't gotten paid, tell them that you will only pay for one part minus the $70 shipping of THEIR part to bosal. They will try to threaten you with a lawsuit and a bunch of bs blah blah blah. Tell them to fuck off and you will only release the funds if they send you an email that they agree to being paid for one part minus the $70 shipping back.

You didn't deal with or order from Bosal, rather Partsgeek.

gkoenig

· #19 · Oct 19, 2012

I recently ordered rear Bosal exhaust, hangers and metal gaskets through parts geek.

First the rear hangers came in about 2 days, the muffler took 6 days, they gave me a USPS tracking number and it vanished online during tracking. It then showed up a day late by UPS. The mid section hangers showed up via USPS on day 7. It appears they all came from different locations.

The muffler box was damanged, rear tail pipes had broken throught the box.

Regarding the fitment, the overall length is about 1.5 inches too short which stretches the rear rubber hangers to the extreme. It also appears that they welded an extension piece on one of the ends that joines the existing pipe. I had to grind the weld in order to get the flange to move down to the end of the pipe.

Overall the fit was doable and I feel that I got what I paid for, the cheapest rear muffler I could find. As for parts geek, after reading this post and my personal experience, they have lost another customer.

GreenZZZ

· #20 · Dec 15, 2013

This for me is a reference thread on Bosal. I put Bosal parts on my RWD '02 E320 with no problems and had the option of local returns (which I didn't need) through Advanced Auto Parts. Just another data point on Bosal.

No Excuse For Thinking: Bosal Catalytic Converter Pipe install on a Mercedes 2002 E320

Also, notice that the cats in this thread have 4 welds vs. the newer Bosal parts have 2. It appears that Bosal has overhauled their manufacturing.

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