Double hung window with cracked covers
I don't think your window is defective. It just sounds like your balances are old and need to be replaced. 15 years is just about the end of a balance's lifespan, so I'm not surprised to hear your description of the damage.
We can help, but we'll need you to remove the old balance from the window and show us a photo of it by itself. I need to see the shoe, spring, and the cover you mentioned. We may need more information after that, but I need to know what to ask for first.
Thanks! That pivot shoe looks like a match for our 15-199, which itself is compatible with two types of coil spring: either the 1/2" thick Series 160, or the 3/8" thick Series 165. You'll have to measure your spring to confirm the better match.
That would depend on which coil balance you have, and how many springs are on each side. Once you've selected your spring, you can see a list of products on that store page under "Related Part(s)," including various covers.
If your old spring is 1/2" thick, and if you have three on each side (which you appear to have), then you can use the 15-150T cover. It doesn't matter if it looks like the original or not, they both perform the same function.
How do I return the ones I ordered.
It looks to me like you have the 3/8" springs, instead. That would be the Series 165.
You can see our return policy here.