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First of all, what is "at speed" mean? With hubs locked in and your moving, the front and rear d-lines are rotating at the same speed. When hubs aren't locked in, the front d-line isn't rotating at all. So, you are trying to engage a rotating force into a gear that isn't rotating. Hence the gears not engaging. You really aren't supposed to engage or disengage the gears while moving. You can to a small degree, but gear'd t-cases don't like it. 4WD gears do have synchro's, not sure about 4LO.But if you had a chain drive you can engage 4wd in at 60mph. That is the one thing I miss about having a chain drive T-case, but they are weaker because of it.
By at speed i mean 10-20mph, although with the hubs locked i have engaged and disengaged the 4wd at 40+ without problems. I get what you are saying about being the driveshaft not turning without the hubs locked, but this never used to be an issue, which leads me to believe something inside the case has changed.
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