I had a similar problem when I bought my truck. WHen in 4x4, light would come on at times, with any power the front axle would pop into 2wd and make a banging noise. Ran hot vacuum to actuator, no fix. Actuator held good vac = OK. Noticed with actuator and cover off, the inner and outer right front axles were sloppy, up and down play. Replaced plastic bushing between axles, but it fit sloppy in the INNER axle. Replaced inner r/f axle, axle seals, 2 plastic bushings, and 4x4 works every time.