Front axle ?
That's probably exactly what's happening, just not in the sense you think. 
Moisture collects in the vacuum lines, and when it drops below freezing, it... well... freezes..... Mine did the same thing. I pulled it into the garage, pointed the torpedo heater under the truck there, let them thaw out, and blew them out with compressed air. Hasn't been a problem since.

Moisture collects in the vacuum lines, and when it drops below freezing, it... well... freezes..... Mine did the same thing. I pulled it into the garage, pointed the torpedo heater under the truck there, let them thaw out, and blew them out with compressed air. Hasn't been a problem since.
Check your metal vac lines that run along the frame. On mine the rubber seal on the cad leaked in moisture and it was completely blocked with rust. Pull the vac lines off the cad and see if you have good vac there first.
If all else fails, you could probably remove the vacuum actuator, and seal that hole. Then remove the 4WD switch off of the other side and jam/j-b weld/epoxy/cross-thread a rod or bolt in there to keep the fork in the locked position. It doesn't matter if you ruin the stock CAD cover, you'll get a new one with the posi-lock. It will need to be liquid-tight, so the 90w doesn't leak out though.
Oh, and your 4WD light will stay on.
Oh, and your 4WD light will stay on.









