[pauloh]

Problem solved. Like Bruce said, another pair of eyes/hands. My buddy and I did grind on one pin a little, then while he was trying the fit (he had watched me once as I tried the brute force method again), he stuck it on there and turned the trunnion bar "in" so that it "crossed" the hitch/ball. It glided right into place. I must say, my buddy had the benefit of never having read the instructions. I had been trying to use the opposite angle "outside". There is a reference to "outside" bar alignment with the bumper in the instructions, and no diagram or explanation about doing it correctly that I comprehend. I hope the photos attached help someone else eventually, I know they would have done the trick for me.

We did not grind enough off of the one pin to do any damage (none to areas Bruce mentioned), took off some paint and maybe 1/32 inch of steel. Both bars feel the same when installed and I will of course keep an eye on them.

So I owe my buddy, and Bruce here on the forum, a beer or something. Thanks again for all the help.