Problem partially solved. Removed the selector linkage and eliminated the vacuum system and manually pushed the 4wd selector in and managed to engage it and drove out under its own steam, happy with that. Now to work out why everything appears to be working normally, but there is obviously a few mm of travel that is not occurring causing it not to engage, might pull all the external linkages apart and give everything a good lube and see if that fixes further issues.
Many thanks for the advice offered, was almost going to be the excuse needed to get Dan's transfer case gears, still something I'd love to do one day.
Dave