Need a little help with 4wd system

Well after an exhaustive search on the interwebs, I need a fresh set of eyes.

I have an 04 Ext Cab Tacoma V6 manual (Lo-Hi shifter, one touch 4x4) that is displaying a bizarre (to me) 4wd problem. I've lost 4wd capability and I get an occasional green, dash 4wd indication light when starting the truck. To be more specific, when the key is moved to ON or ACC during the starting process, the light is present. Cycle the ignition and it's gone.

The front drive shaft is engaged however, but the front diff is not locking. By referencing what appears to be the freely available 2003 FSM I confirmed my 4WD button has good continuity, but when I try to start trouble shooting the electrical connections at the t-case/actuator from the 4WD ECU, the connectors appear different than whats in the manual.

Did Toyota change the t-case between '03 and '04? Is there an '04 FSM floating around?

My next step is to try to jump start the actuator to verify it's actually working, but I'm out of luck until I can get the pin out.

Guys, any and all help would be appreciated. I'm the second owner of my truck and the 4WD system has seen hardly any use. Which reminds me, I last successfully used 4WD at my deer lease in Dec and when I went to disengage, the light stayed on after the front diff was unlocked. Cycled the ignition and viola!

Thanks for the help guys!

 

Update...

Took actuator off the t-case and confirmed that the brushes are good and motor turns. The actuator rod however, did not come out of the transfer case with the motor and was really stiff. After a little massaging it moves freely but still won't come out. As I pull the rod aft, the front drive shaft gets a little play in it, and when I push the rod forward, it tightens up the front DS, as it should.

Does that rod remove freely from the t-case with the actuator motor? That might be my first issue right there.

Thanks for the help.