Brand new Gator xuv 550 S4 makes grinding noises when using 4 wheel drive!
First you need to verify that it is only in 4 wheel drive that it makes popping or grinding noises. Check to see if there is the appropriate amount of oil in the transmission. After you've confirmed that there is the proper amount of oil and the noise only occurs when you are in 4 wheel drive, remove the front driveline where it comes out of the transfer case. With the Gator on jack stands so that none of the wheels touch the ground run it to see if the noises have stopped. If so then it is coming from your front end. If not then it is coming from your transfer case. Remove the transfer case to verify as you may have gear teeth in the transfer case missing or broken.
