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The numerical solver that KDL and Trak_IK use are really just meant to work with arms that are 6 DOF or more. The fact that you're even getting solutions 5 out of 6 times is a little surprising to me and might just be a bit of luck.
In the KDL mailing lists you can find some suggested workarounds to using a 5 DOF arm, but personally I've tried them and haven't had any luck.
The best suggestion I can make from my experience is to use the IKFast solver from OpenRave and use the TranslationDirection5D solver type. Luckily this is something common enough that there is a nice way to do it with Moveit and there is a tutorial that describes the process here. Note that instead of --iktype=transform6d you'll want to use --iktype=translationdirection5d (I think it is translationdirection5d, the exact text might be something similar but different).
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