If the feel has changed moving it by hand then you might have a gear stripped or warped. Could happen if your push rod is at an angle which is creating a mechanical stress on the servo and warping gears as it tries to work.
If you are worried about the noise, this digital servo is a high speed servo and under no load it will make wierd noises as and even oscillate a bit if you put a longer arm on it .. As its trying to find the true position and oscillating and the finest touch will make it calm down. In flight all servos are under load so they don't cause issues .
If you are worried about the gear, and notchiness, open it, inspect it, grease it and put it back together. Even sometimes an angles mount (not 90) will cause the case to warp and Gears not align properly. Unlikely on such a big servo, and unlikely till you are just smacking the crap out of this bird. But it can happen.
So check that for peace of your own mind
