I had no problem reproducing the failed N. Africa creation.
For test I replaced all French units in the colonies that are at ports with British divisions in garrison mode.
I left one French HQ on the fort hex in Tunisia because it wasn't a port and I didn't want my UK unit trapped there.
1. Jun 21 - Gr take Paris reaching the 41 morale level for France to cause it to surrender.
2. Jun 21 Allied - Allies see notice that Fr will surrender. At this point I meant to withdraw all UK forces from future Vichy but I missed the message in the PBEM game and didn't. So I leave everyone in place.
3. Jul 5 Gr - Germany accepts the French Surrender and all French units disappear.
4. Jul 5 Allied - Messages say France surrendered and Vichy France is formed.
Messages say Vichy Syria is formed and stays loyal to Vichy.
Messages don't mention N. Africa.
There is no Vichy North Africa.
All the UK divisions in N. Africa ports remain in place.
All hexes outside of those ports are marked German.
UK units in now Vichy Syria are removed and placed in Palestine.
I saved the log files but they don't show anything unusual if you want them.
I also saved each turn before and after Paris falls and after France surrenders.
Here is a screen shot of Allied situation on Jul 5 turn.
