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TECHNICAL CASE STUDY 10 MIN READ DECEMBER 2025

The Universal TPMS Problem: How We Fixed What 40+ Brands Couldn't

How systematic problem-solving grew MaxSensor's US market share 3x from 2017 to 2024 — and what it taught us about building tools that actually work.

EW

EWNexus Team

December 2025 • Based on 2017–2024 project work

// TL;DR: We built a 8,000+ vehicle compatibility database, cut TPMS failure rates from 12% to under 3%, and helped MaxSensor dominate the Universal TPMS category in the US aftermarket.

What Is Universal TPMS?

Every modern vehicle sold in the US after 2008 has a Tire Pressure Monitoring System (TPMS) — sensors inside each wheel that warn the driver when tire pressure drops. When a sensor fails or a wheel is replaced, it needs to be reprogrammed or swapped.

OEM sensors are vehicle-specific and expensive — often $50–90 per sensor. The Universal TPMS category promised a single sensor that could be programmed to fit any vehicle, at a fraction of the cost. For auto shops, this was enormous: carry one SKU instead of fifty.

The promise was real. The execution — across most of the market — was not.

The Real Problem

Vehicle TPMS is not standardized. Different manufacturers use different RF frequencies (315 MHz vs 433 MHz), different communication protocols, different relearn procedures, and different antenna placements. "Universal" sensors were built to cover the majority — but the edge cases were killing trust in the entire category.

Common failure modes in 2017

  • Sensor programmed but TPMS light stays on — protocol mismatch
  • Relearn procedure completed but ECU doesn't accept ID — frequency issue
  • Works on driver's side, fails on passenger side — antenna placement
  • Works initially, drops out after 10 minutes — signal strength

At the time, 40+ brands were selling "Universal TPMS" sensors in the US market. They all published compatibility charts. Those charts were theoretical — not verified. Shops had been burned so many times they were skeptical of the entire category, regardless of brand.

The Situation in 2017

MaxSensor was entering the US market as a new brand. The Universal TPMS category was the growth opportunity — high volume, strong shop demand, recurring replacement business. But the trust problem was industry-wide.

The approach from most brands: publish a coverage chart, claim "97% vehicle coverage," and let the sales team handle objections. The shops that got burned became skeptics. The shops that didn't try at all stayed with OEM.

Our approach was different: instead of marketing our way around the problem, we decided to actually solve it.

The Systematic Approach

We started with a simple question: for every vehicle in our coverage list, does the sensor actually work — and if not, exactly why?

We built a testing protocol. Every vehicle application was classified by:

FREQUENCY

315 vs 433 MHz — does the sensor transmit on the right band for this vehicle?

PROTOCOL

Does the sensor speak the right data format for this ECU?

RELEARN

Exactly which relearn procedure works? OBD, stationary, or drive relearn?

ANTENNA

Does valve stem orientation affect signal reception on this model?

Each result was documented: confirmed working / confirmed failing / workaround available / tech notes. No theoretical coverage claims — only verified results.

The Database

What started as a testing spreadsheet became the core competitive asset.

2,000

Vehicle applications at launch (2017)

8,000+

Verified applications by 2024

100%

Tested, not estimated

Each entry included the exact relearn tool required, the exact procedure steps, known vehicle variants that behave differently, and field-reported edge cases from shops. When a shop called with a problem, we had an answer — not a guess.

The Tool We Built for Shops

The database was only useful if shops could access it. The old model: a PDF coverage chart. The new model: a VIN-based lookup tool.

A shop enters the customer's VIN. The tool returns: compatible sensor SKU, exact relearn procedure, required tools, known issues for that specific vehicle. 30 seconds instead of 10 minutes flipping through a coverage chart — with a definitive answer instead of "it should work."

Before vs After

BEFORE

"This sensor covers 97% of vehicles" — shop installs, fails on edge case, returns product, never buys again

AFTER

VIN lookup shows exact procedure for 2019 Honda Pilot — shop installs correctly first time, calls back to reorder

The Results

3x

US Market Share

2017 → 2024

<3%

Failure Rate

Down from ~12%

8,000+

Verified Vehicles

Tested, not claimed

Shops stopped calling to complain. They started calling to reorder. The VIN tool became a sales tool — distributors used it to demo MaxSensor to shop owners. "Enter your hardest vehicle" — and it would answer correctly every time.

The brand that solved the real problem didn't need to compete on price. It competed on trust — and trust compounds.

What This Means for Your Business

This case isn't really about TPMS sensors. It's about a pattern that works in any industry:

1

Find the problem everyone has but nobody solved

In TPMS: compatibility failures everyone accepted as "normal." In your business: what do your customers complain about that nobody has fixed?

2

Build the tool that removes the friction

In TPMS: VIN lookup tool. In your business: maybe it's a quote tool, an inventory checker, or an online ordering system.

3

Let the product do the selling

When something works reliably, customers tell other customers. You stop competing on price and start competing on trust.

This is the approach we bring to every small business we work with. We ask: what's the real friction your customers experience? What tool would remove it? Then we build it — at a price point that actually makes sense for a small business.

Want us to apply this thinking to your business?

We built the TPMS database. We can build the tool that removes friction for your customers too.

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