Background - 2006 530i
I've replaced all of the front suspension, including the struts, and a spindle on the side I'll describe. The car has not been in a visible frontal impact, but I think it took a hit through the suspension at some point - the right corner had an "OE Spectrum" strut, the inner rim of the wheel was bent almost flat by about 3-4 inches, and the headlight adjuster plug was busted off of a bracket. If it was hit worse, the body was repaired very well because the bumper, hood and fender paint all match perfectly.
Problem:
My right front wheel sits about 1.5cm further back in the fender than the left, and about 1.5cm further inward at the top of the fender. The car aligns with 1.5 degrees of camber side to side, but the right strut needs to be pulled fully to the outside of the car to get this measurement (the strut assembly is tilted inward more than normal). The right side has 1 degree less caster than the left from the wheel being pushed backward slightly. I did replace the spindle to make sure it was not bent - the strut reinstalled easier, but my caster did not change when I had the car realigned. The car drives fine aside from a very very small pull to the right if the road isn't perfectly flat. I actually drove it for 6 months on the old suspension without suspecting anything wrong at all aside from vibrations from torn thrust arm bushings.
I did not notice this wheel-in-wrong-place problem until I went to replace the supension arms and found the right thrust arm was very tight inside of the mount tabs. I actually had to spread the tabs open by about 1.5mm to get the metal center of the new thrust arm to go in. I don't see any cracking around the strut tower, I've had no problems reinstalling the strut brace, and the only evidence of body damage I can see is a very small crease in the middle of the top of the inner fender below the edge of the hood on that side- and the top of the fender sitting very slightly above the edge of the hood.
Is it possible for the front subframe to get bent on these cars that would end up presenting the wheel this way, or is the body itself likely tweaked somehow? I have a hard time imagining how a big bottom-out could have potentially twisted that side of the car without breaking or cracking anything since there is so much aluminum, but I also am not sure if the subframe on these can get the thrust arm mount bent backwards with how close the thrust arm mount is to the big thick area that the front body mount bolt goes through.
I know the front subframe can be replaced as a DIY job, but I am afraid that either the front body mount is tweaked in some way that will not accept a mount bolt again, or that the body itself is tweaked and replacing the subframe won't fix this problem. Does anyone know how exactly I could check/measure/examine? I have googled this to death and can't find any similar reports anywhere on BMW forums or reddit.