During a suspension inspection, what type of wear on the assembly is considered unacceptable?

Visible cracks or material separating from the assembly are significant indicators of a compromised suspension system. This type of wear can directly impact the safety and functionality of the vehicle, as cracks may lead to structural failure while driving. The integrity of the suspension system is crucial for maintaining proper handling and ride comfort; any signs of severe deterioration, such as cracks or separation of materials, suggest that the components may not perform as intended and could pose a risk to the driver and passengers.

Other types of wear, such as minor scratches, discoloration, or surface rust, while they may indicate some level of wear or aging, do not necessarily compromise the structural integrity of the suspension system in the same way. Minor scratches may be cosmetic, and surface rust can often be treated or might not affect the functionality as long as it's not extensive. Discoloration often results from exposure to elements but does not typically indicate mechanical failure. Therefore, the presence of visible cracks or separation is a critical factor in performing a thorough and effective suspension inspection.