I would guess you will have to pull the pto rear unit out to investigate. Can't say I have seen one do as you say for making noise inside rear case. Far as engaging the pto, there is a partial engagement stage on all those models. This is to get the machine rolling before you fully engage the pto. You should be easily able to feel this when pulling pto lever as it contacts a quite heavy spring well before linkage goes over center to full engage position. That pressure is also adjustable and should be checked when ever pto pressure is set. It is a seperate and more invasive adjustment than the max pressure adjustment. Even running full rpm you should be able to engage pto slowly if you do so carefully.
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