I am trying to replace parts in an assembly and some work smoothly others are painful. The part templates are the same and modeled the same. I am using planes and face ID's. Orientation of the part comes in correctly but face coincident mates become "suppressed invalid or no longer exist". I have tried to scrap the face id's and insert planes because they are always there. Neither works. Still have broken mates. It would not be critical if I were simply just able to edit but I am in the process of a DriveWorks implementation and I would like to be able to automatically generate models without errors and having to edit. I also see that there is a Development group working on this issue. If anyone knows a better way to avoid these errors it would be greatly appreciated.
I have had this happen many times. Usually it will correct itself with a little encouragement. If you replace the part, and go ahead and accept whatever it tells you. Then in the Design Tree (on the left), select the mates that failed, then right click and edit feature. This should bring up the mate dialog box. I have found, if you fix the first one, then the others usually resolve themselves. If this doesn't work then you usually have to redo all of the mates.
I had a similar situation the other day. In my case, the solution was to flip one of the mates on the one that had the error and that cleared all errors. Seems that when the part was replaced (actually it was the same part with same features- different configuration so all internal IDs were the same), it flipped the mate alignment.
As far as I can tell the mates will not solve when the parts are created individually.