When I bought my '98 it had 4x4 issues as well. I was disheartened to find the actuator on the front diff was broken off, not the actuator itself but the aluminum mounting tab on the axle housing. and to make matters worse the broken off piece was gone.

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Following are the photos of the steps I took to "engineer" and attach a new mounting point for the actuator. Proud to say it worked great and I never had a moments problem out of it.

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Couldn't use but two of the three holes.

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A bit of JB Weld to get everything positioned correctly.

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Weld up the bushing..

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I will mention here that not only does this system require vacuum to engage 4WD, it requires vacuum to hold it in 2WD.

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And here is the vacuum reservoir under the right front fender that apparently gets broken with very little fender damage and makes lots of things go haywire.

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nice write up!

 

The "engineering" part will probably not help anyone but the vacuum info may. I have another experience to post, ring gear bolts fell out. LOL, later.

 

It may, if your broke like that, I'm sure someone else's did too!

 

This was very informative