turbodog -
I have the identical hitch and it does state in the owner's manual that the pins should be put "through the holes in base rails from the inside out .... so the cotter pins are on the outside of the base rails". In 2 of the 3 diagrams in the manual, they are inserted in this way but on the front page diagram, they are put in with the cotter pins on the inside of the rails. Go figure.
Not sure why they have to be inserted this way unless there is a chance that the cotter pins might get in the way of the hitch moving from one position to another.
Do you have the hitch properly seated in the retention holes? There is a stopper/keeper that falls into the retention hole when it is aligned properly. Perhaps the hitch is riding on top of the rail rather than being locked in place by the keeper and the retention hole. (??)
As you described the problem, it certainly is a cause for concern. There shouldn't be any need for you to bang it over to engage it and the parts should go in and out without binding.
Is this a recent problem or one that suddently developed?
You don't need to be going down the road and have your hitch sliding back and forth between the towing and the maneuvering positions. It should be firmly locked in one position or the other.
Before hitching up, try manually moving the hitch back and forth. If it jumps out of position or you can move it, it is not being locked into position.
Sorry - but not being much help other than reinforcing what you have already been doing.
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2008 Cougar 5th Wheel 27RKS
2005 2500 GMC Duramax
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