Sorry to ask the 4 low question again but...

I'm sure my question has been asked many times, but my searches here didn't show my question on the search engine for this site(?):
I've owned several 4X4s, including mostly Toyotas, and have driven them on and off road for 35+ years in my own trucks, both in the U.S. and in third world countries driving Diesel engines Hilux and Prado's. I'm now retired from my Park Service job. I bought my current 2005 4 cylinder manual shift Tacoma new.
Now I'm able to shift it into and out of 4WD high with no problems, but to get it into or out of low range, I must shut off the engine, restart it, and it then goes into or out of low range instantly with no problems (my wife suggested trying this and it works for our problem). It will not go into or out of 4WD low unless I shut it off & restart, despite doing what the manual says and what others here have recommended. Also, even though it is definitely in low range (and works as it should in low range), the 4WD low warning light continues to flash constantly when it's in low range. When I want to take it out of low range, once again I shut it off, restart, and it then easily comes out of low range & the 4 low warning light goes out. I've always "exercised" the 4 WD every couple of months for a few minutes, just to keep it working, and actually use 4 low about 20 times per year.
Does anyone have any thoughts as to what the problem is? My local Santa Fe, NM dealer wants to be paid for looking at it, and refuses to even hint at what the problem might be even though he said that he's heard of this previously. I'm pretty good at self-repair for most of my problems, but not sure about this and hate spending $ on what might be a common complaint.
Thanks for your thoughts!

 

This is why I like mechanical engagement (lever) over all the electrical engagement/throttle by wire bullshit but mr. ding might be on to something here...

 

I knew you would, you grab the lever & you KNOW it's going to engage/disengage

 

Isn't that the truth! Manual Hubs and a TC Lever are always my favored option!

 

We had to give up those things so we could get a rear window defroster and 13 power cup holders.... Uh....er....So we didn't get those either. I'm gonna start a thread complaining about THESE things.

 

2009 V6 4X4 - Myself and another person on here have a similar problem, although not specifically the 4 low position. My 4x4 ECU seems to loose its memory somehow - can shift on the fly between 2 hi and 4 hi, but at times, shifting from 2 hi to 4 hi doesn't happen, no lights or anything. Turning the vehicle off and then on seems to reset something and normalcy returns.

Usually the off / on thing has to be done up until 3 times and then the system works correctly - 2 hi, 4 hi, 4 low.

Dealer can''t find problem as it happens intermittently and they probably aren't spending a lot of time on trying to find problem until something breaks.

I don't know enough about the wiring routing to figure out if the 2 hi/4 hi light doesn't come on due to one of the actuators (front diff / transfer case) not working, or if it is an electrical problem central to the 4X4 ECU.

 

I miss the days when I had to look over at my girl friend ( now wife ) and then she would say, I know get out and lock the hubs in. ( CJ5 jeep )

 

I just want 2 low And a neutral in the tc.

 

My dad's new to him 87 T4R. My favorite part of the truck.

 

I know right!, I didn't really have one in my 1st gen. Jumped in a 2nd gen & theres cup holders everywhere....

You know it brother , & you've got a keeper there for sure, I had manual hubs on every other 4x I've had...

 

Thanks guys, esp Door Ding, I'll post at that other place and see if anyone has an answer. This is a great site to read about these trucks!