TampaDave, several years ago I had about what sounds like the same issue. I watch outside while my wife extends the slides. Our large side started out but I could here it starting to bind up. Looked up quickly and saw the slide cover not rolling out and was getting so tight that you could have been able to play a tune on it. Hollered at her to stop which she did. I went up on our traveling ladder and the awning tube was tight. After "massaging" it a little, it finally stared to unroll and I heard something "pop". After it did come out I took thee assembly apart and found the spring mechanism was hanging up on a rivet. Drilled out that rivet, installed a slightly shorter rivet and it has been find since. I would say something is binding up your roller somewhere.