The vacuum actuator on the fender, pulls a cable that goes to the front axle to engage, sounds like you already know that. There is a vacuum switch on the t-case that when shifted to a 4H/4L sends vacuum to that actuator on the fender. A few problem areas for those were vacuum lines rotting, cracking or rodent chewed. T-case vacuum switch picking up fluid and ATF eating the vacuum diaphragm in the actuator, if ATF is found in switch or actuator the t-case was either overfilled, or rear trans seal is leaking and overfilling t-case.
If you can't find a problem or don't want to put a lot of time or money in it then try a cheap fix. If this truck stays off road, or most of the time and you can disconnect actuator and pull cable to engage frt axle. Use whatever you want to keep cable pulled for 4wd.
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