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Paul
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1) That crack doesn't look good. The bearing could be loose up there. That might affect the the brushes. Maybe if that round part fits snug into the cap that might hold it together some but slop in a bearing seat is not good. If the bearing is vibrating or spinning in the seat, it will likely get worse. Maybe they dropped the router or replaced the bearing with a 'close' one.
2) The plunge base looks like a different manufacturer. 335 instead of 315 (Ryobi). Try it.
3) The manual mentions the collet is 1/4".
4) No idea ;-) is there any sign of it inside the cover?
 
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