Just replaced the actuator to get the front axle to work again in 4wd.

New problem! The vacuum to the actuator is on all the time keeping the axle engaged even when in 2 wd.

I replaces all the vacuum hoses in the truck first. See here:
http://www.automotiveforums.com/vbulletin/showthread.php?t=498411


I thought I might have hooked up the hoses to the transfer case backwards so I switched them, but that didn't fix the problem.

Ideas?

check / replace the transfer case switch (the one that the 3 vacuum lines plug into on the transfer case)

check / replace the transfer case switch (the one that the 3 vacuum lines plug into on the transfer case)



That's what I figured. Picked one up earlier tonight to replace tomorrow.