Is it possible to bring back a feature that was present until 2.3.0? When you split a part and select surfaces and merge the split parts back, the selected surfaces which is now inside the part, vanishes. If you select FE based surface, it stays but when you apply pre-tension load on that surface, there it faces issues.
In one of my previous projects,
In the end I had to keep the split parts separate, al though this is not a huge issue, but when I have many parts in the simulation, it is hard to keep track.
Keeping the split parts separate won’t be an issue as long as the part count is low. If I use lots of bolts say for example in a flange, then the part count nearly doubles and it will be hard to track contact surface pairs and since there is no way to rearrange the part list in prepomax, all of them are jumbled up here and there and sometimes I pair the wrong surface and the model never converges. It is not a deal breaker but it was a nice feature till it was there.
The reason why the internal faces do not work any more is by desing.
After some problems with internal faces after the neighbouring parts are merged (in PrePoMax, only parts can be hidden, so after merger, the internal faces can not be reselected by the user or automatically), I decided that keeping internal faces which cannot be used later is not useful. And it is also topologically incorrect.
So this will stay as it is. However, I also see the need to be able to organise items in the tree, so I will look into adding support for moving and grouping tree items. In this way, the problem you describe can be solved in a correct way. It will introduce some additional work, but it will bring a better user experience for the future.