The hub caps will work fine so long as it can still block the sleeve from coming off. I’ve ridden mine with chunks of metal missing due to them getting beaten up by road debris without any issues.
I would try switching to the new sleeves and seeing if the noise goes away first since I have never had mine make that noise and it seems like it could be from the sleeves. Not 100% sure though
Also cheap china made hub motors are what I have too and they are still working despite plenty of abuse over more than 2 years. Well designed cheap china hubs are near indestructible
That is just the sleeve getting damaged by the metal hub. Based on this photo:
Your hub uses the same style for the sleeve grooves as mine which have the downside of destroying the sleeves over time. So long as they don’t blow out and just the grooves get bigger then they can still be used. Just might want to super glue the hub to the motor and then assemble like normal.
That noise is a bit odd though and something does seem to be messed up. You need to remove the inner screws, get a hammer out and tap that inside hub cap off. Once removed you can just firmly pull the rotor off the strator. Hammer won’t work though since you have to keep pulling it without stopping or else the magnets pull themselves back into place.
The post photos so I can help. Or just DM me if you want
Ahh, the 'ol motor disassembly procedure. I was hoping to avoid this but I guess motor bearings do go eventually… And with all the salt on the roads recently…
Will post stator pics when I can. I was really hoping this was a sleeve interface issue.