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Your vacuum leak is the problem. Start at the top and work your way down as described above or at the bottom and work up. Mine had leaky hoses between the T-case and the actuator. I drove it for a couple years with it occaisionaly popping out of 4X4. That wrecks the splines on the axle shafts and then they don't work with good vacuum.
Just about anything can be the problem, start testing at one end and work your way to the other.
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'94 3500 4x4, 299,000 miles being converted from a bent Standard Cab to an Extended Cab. And adding twins. And a ported head. With studs. And DDP 4's.
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