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It is possible to have the vacuum lines on backward. If the light is on, the shift fork is engaged on the vacuum motor. If that is on while the transfercase shifter is in 2WD try to reverse the direction of the vacuum hoses. If the front driveshaft is spinning while you are in 2WD then the shift motor is incorrectly engaging the front passenger axle. Also, if you put the tcase in 4wd and the 4wheel drive light turns off then the vacuum lines are reversed. I think you're on the right path for hunting this down. Unfortunately, I don't know of any online sources for specs on this. If you have a 4WD hardware catalog you'll see the schematic for the YJ front D30 axle assembly.
Good luck!
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Jeff
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