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Your problem may be something is blocking the wheel placement when you place the wheel/suspension block.
Are you or another block in the way? If you are in the way it will place the suspension, but not the wheel as these are two different blocks.
Is your vehichle and the area the wheel occupies above ground level? You can't place a wheel if it initially interects the ground. You can use a pistion as a hydraulic jack to raise one side of the vehicle to mount the wheel.
It appears that there is a bug which marks wheels as trash and later the wheels will be removed if trash removal is set.
This also seems to be the case if I try to place a suspension wheel on a station apparently - or something static (not entirely certain on this but atleast station).
However, if I build everything on the scuttler, and then disconnect it from the project, and try to put a wheel suspension on, the wheel will appear - even with less room for it, obvioulsy this won't work, as the vehicle will be on the ground and the weel wont be able to lift it up from the ground.
Having free room here isnt an issue at all, as it doesnt seem to matter how much free room it has - like explained above, even putting it onto the ground station, with the wheel up into the air won't work either :/
Bottom line the wheel may be too close to the vehicle.
So I need to put an armor block to have it stick out more ?
That's kind of odd, as I actually did remove one of the suspensions after I disconnected it from the projector, and put a new one into the same hole the first one was in with the wheel appearing o.O
I also built the Scuttler for the easy start world.
I had to start by making the blueprint projection 1 block higher, and when I got to the wheels I had to crawl under the vehicle becase if you try to weld it from the outside, your own character model seems to block the wheel area and it won't place it.
Alot of the things on that easy start world seem really, really poorly designed.
I suppose that's to force you to not use them for too long and design stuff yourself.
I was having the same issue and I finally figured it out. I was able to place the suspension on small ships and have the wheel pop out most of the time; but, not always. Then for large ships it would never pop out. It seems that if I was too close to the suspension when placing it, my body would obstruct the wheel preventing it from popping out upon placement. So, the answer is to stand to the side so your space engineer is not occupying the space the wheel needs.
I am sure that it is a similar issue with projectors. I imagine that the welder is obstructing the wheel placement when the block is created.
This has to be one of the greatest necros I have seen so far.
How do people even manage to find these ancient threads?
https://lmgtfy.com/?q=Internet+search+engines
:P