Hey Geoff
Did you figure out why it leaked?
Were you able to come up with a better sealing method?
No idea. I had the cover of the trim housing open when I first got the motor, it was clicking and I had to adjust tension on the trim housing motor. I guess it's possible I didn't put the seal back together that well? It took two seasons of some pretty major saltwater use to ruin that tiny motor. self-inflicted? Maybe, maybe not. Never know.
What I do know is this trim motor doesn't make any clicking, so I'm not opening it if I don't have to. Maybe it will stay sealed.
I may run a bead of silicone around the seal but then again, I shouldn't have to. Plus, if I have to open it for any reason it would be a PITA.
Last year I had to replace the 3 batteries I torched... this year the trim housing... seems it's costing about $300 a season to run this Ulterra.