Can sensors leak or split apart?

Our sensors are sonic welded shut and can withstand close to 1,000 PSI of internal pressure when the o-ring protecting the circuit board is intact, so, from a design standpoint, it's not possible for sensors to leak or split on their own. However, when sensors are in use, there are a couple of ways sensors can be damaged, which can cause leaks or splitting:

Scenario #1: While driving, debris from the road (usually something like a piece of asphalt or a small pebble, etc.) is kicked up by the tire and it impacts on the side of the sensor, thereby weakening the internal integrity of the weld or unseating that internal o-ring. Sometimes, this can cause an immediate split. Other times, this weakening is gradual, causing it to leak or split at a later point. When this occurs, please reach out to RVi customer service so we can replace your sensor. These are one-off situations that are very, very rare. 

Scenario #2: A sensor is less than 1" from the rim or outside of the tire. Even on solid metal stems, you can see quite a bit of movement from the centrifugal force generated while driving. This causes the sensor to vibrate and potentially impact on the tire/rim itself. This acts like a jackhammer on the side of the sensor, leading it to leak or split once the weld's integrity is weakened to a certain point or the o-ring becomes offset. The symptom for this issue would be seeing multiple sensors leak/split. This is the only scenario in which we would see multiple sensors exhibit this behavior. When you contact RVi Customer Service Champions, we will replace your sensors - however, we also will require you to install some 1" valve extenders (that we provide) to move your sensors further out from the tires. This will prevent sensors from impacting and having this issue again. Failure to install the recommended valve extenders will be taken as forfeiture of your warranty for this particular issue going forward, if it ever were to happen again.