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I've brought this up before but i have a 99 f-150 that the center disconnect is not working, transfer case engages actuator moves at the axle and pushes on the arm but still no front engagement. what may have failed in there?
how do you know the actuator moves? if it moves it will slide a splined ring that locks the axles together. If you are certain this works then there may be something broken inside. Only way to be sure is to remove the front differential housing. Its not too hard.
I've had somebody operate the switch while it was running and I tried to help it but without the truck rolling it might not engage so it would not move any farther than the actuator will move it