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I'll be watching this post too, hope you don't mind me piggy backing. I just got a 2000 Excursion and the auto lock doesn't work so I've been driving around with them manually locked. I was told it was a vacuum leak but I have no idea how to find it.
Why do you have to use pliers to lock them? That sounds like you have more than a vacuum issue? Or I guess since your talking about replacing the hubs its both a bad hub and a vacuum issue?
Will a vacuum issue lead to bad hubs or can you go indefinitely manually locking hubs and leaving them locked during the winter and then manually unlocking them for the summer?
2000 Ford Excursion 7.3, AIS intake, 4" MBRP exhaust, PHP Hydra Chip, Bilsteins (5100 in front and 4600 in back) and x code front springs to be added when I can find the time to put them in.