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#1
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I had same thing happen to a Tunze pump, the black outer layer is indeed just for show. The motor likely has an internal seal. However you will want to seal it up again, I didn't and it created a very tiny capillary-like siphon that drew water up the cord and deposited salt water into the controller.
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#2
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Had that happen to two of mine. Dealing with any type of warranty issue is a joke with Maxspect and J&L, even though it's more of a safety issue. J&L tried to pawn off on the manufacturer saying it was a "grey market" thing. I just bought the newer models instead, from Reef Supplies. Sorry I'm of no help, but seems like a common problem
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