Given a system of $N$ point-particles with positions
${\bf r}_1, \ldots , {\bf r}_N$; with corresponding virtual displacements $\delta{\bf r}_1$, $\ldots $, $\delta{\bf r}_N$; with momenta ${\bf p}_1, \ldots , {\bf p}_N$; and with applied forces ${\bf F}_1^{(a)}, \ldots , {\bf F}_N^{(a)}$. Then d'Alembert's principle states that
$$\tag{1}\label{eq:1} \sum_{j=1}^N ( {\bf F}_j^{(a)} - \dot{\bf p}_j ) \cdot \delta {\bf r}_j~=~0. $$
The total force
$${\bf F}_j ~=~ {\bf F}_j^{(a)} +{\bf F}^{(ec)}_j+{\bf F}^{(ic)}_j
+ {\bf F}^{(i)}_j + {\bf F}_j^{(o)}$$
on the $j$'th particle can be divided into five types:
applied forces ${\bf F}_j^{(a)}$ (that we keep track of and that are not constraint forces).
an external constraint force ${\bf F}^{(ec)}_j$ from the environment.
an internal constraint force ${\bf F}^{(ic)}_j$ from the $N-1$ other particles.
an internal force ${\bf F}^{(i)}_j$ (that is not an applied or a constraint force of type 1 or 3, respectively) from the $N-1$ other particles.
Other forces ${\bf F}_j^{(o)}$ not already included in type 1, 2, 3 and 4.
Because of Newton's 2nd law ${\bf F}_j= \dot{\bf p}_j$, d'Alembert's principle $\eqref{eq:1}$ is equivalent to$^1$
$$\tag{2}\label{eq:2} \sum_{j=1}^N ( {\bf F}^{(ec)}_j+{\bf F}^{(ic)}_j+{\bf F}^{(i)}_j+{\bf F}_j^{(o)}) \cdot \delta {\bf r}_j~=~0. $$
So OP's question can essentially be rephrased as
Are there examples in classical mechanics where eq. $\eqref{eq:2}$ fails?
Eq. $\eqref{eq:2}$ could trivially fail, if we have forces ${\bf F}_j^{(o)}$ of type 5, e.g. sliding friction, that we (for some reason) don't count as applied forces of type 1.
However, OP asks specifically about internal forces.
For a rigid body, to exclude pairwise contributions of type 3, one needs the strong Newton's 3rd law, cf. this Phys.SE answer. So if these forces fail to be collinear, this could lead to violation of eq. $\eqref{eq:2}$.
For internal forces of type 4, there is in general no reason that they should respect eq. $\eqref{eq:2}$.
Example: Consider a system of two point-masses connected by an ideal spring. This system has no constraints, so there are no restrictions to the class of virtual displacements. It is easy to violate eq. $\eqref{eq:2}$ if we count the spring force as a type 4 force.
References:
- H. Goldstein, Classical Mechanics; Chapter 1.
$^1$It is tempting to call eq. $\eqref{eq:2}$ the principle of virtual work, but strictly speaking, the principle of virtual work is just d'Alembert's principle $\eqref{eq:1}$ for a static system.