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I’ll check for sure tomorrow but I’m pretty sure you could just take the cv axles off and run the 4wd spindles.
Are the bearings worn?
The directions my thoughts are going is if you still need the support for the bearing pull the CV axle and and cut it off. (See pic, you’d have to make sure to leave enough of the axle on the back side so when you tighten the axle bolt it will squeeze it and keep everything tight. If you still ha e the differential in the expy that’s but 3 bolts and it drops right out(save some weight and would make for a nice little resell value.) Not sure if the 2wd spindles are bolt up and I’m also not sure what kind of check lights would come on swapping in the 2wd spindle. You’d also have to block off vacuum lines that go to the hub. ABS MIGHT be a little different.
Just a thought, you could try running a full vacuum line and bypass the actuator to keep your front hubs unlocked. The hubs on these expeditions are locked without vacuum. The vacuum pressure overcomes the spring on the lock. Kind of a nice fail safe if you were to lose vacuum you would still have 4WD. So it COULD possibly be your actuator is bad or the relay/fuse to the actuator. Yes I know it’s a pretty backwards setup most vehicles hubs lock under vacuum. Stumped me for a bit when I lifted the front end of the bare frame and started spinning the wheels and noticed my hubs were locked in. Still your most simple fix would be to buy wheel bearing hub assembly for a 2WD and see if they work and if they don’t make sure you can return them.
