Case Number: S2522000001
Release Date: Aug 2025
Symptom/Vehicle Issue: TPMS Handling & Installation Best Practices
Discussion: TPM (Tire Pressure Monitoring) Sensor Handling and Installation Practices
1. Tire Dismounting for sensor protection
- Add white mark to the sensor valve to determine if rotation occurs during Tire
Dismounting.
- Follow the tire changer manufacturer's instructions to remove the tire from the
wheel, while carefully observing the following steps to prevent damage to the Tire
Pressure sensor:
- Adhere to the equipment guidelines, ensuring special attention is given to avoid
contact with the Tire Pressure sensor
- When loosening the tire bead from the rim, avoid using the bead breaker in the area
surrounding the Tire Pressure sensor (this applies to both the upper and lower
beads).
- After the bead is broken, apply lubricant on both wheel flanges to the assembly
before proceeding with dismounting. This helps minimize the risk of sensor damage.
- When preparing to remove the tire, carefully insert the mounting/dismounting tool
within ±10° of the valve stem position. Use this method for both the upper and lower
beads to ensure safe removal.
2. Initial Inspection and Sensor removal
Sensor and valve Inspection
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
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Stellantis US LLC

Version 4.5 07/22/2022

- Check that the white mark previously added to the valve stayed on same position
prior tire dismounting.
- Inspect the Tire Pressure sensor housing and potting for cracks or wear.
- Check the valve for stress marks or aging.
- If any damage is found, do not reuse the sensor or valve.
- Document Sensor position and condition prior removal.
Sensor and valve Removal
- Remove the sensor enclosure before removing the Tire Pressure sensor valve to
prevent damage.
- Use a valve anti-rotation pin (if available) to stabilize the valve while loosening the
screw.
- Use minimal force to avoid damaging the sensor housing.
- Pull the sensor enclosure off the valve carefully.
- Push the valve downward to release it from the rim.
Considerations
- If any damage is found or created, do not reuse the Tire Pressure sensor or valve.
- If tire sealant is detected, clean the sensor with a damp cloth to remove residue.
- If tire sealant is detected, thoroughly clean the rim and valve hole before reinstalling
a sensor or valve.
3. New Sensor Preparation and Installation
Verification
- Verify part compatibility before installation.
- Do not use valves older than 12 months (check WWYY date code).
- Always Install a new screw and valve.
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC

Version 4.5 07/22/2022

- Ensure the Tire Pressure sensors are compatible with approved configurations.
- Do not install OEM Tire Pressure sensors in unapproved wheel assemblies.
Sensor alignment:
- Ensure rim hole and sealing surfaces are clean before installation
- Ensure the transmitter is horizontal and not touching the rim before installation.
- The the Tire Pressure sensor must be flush and concentric with the valve hole.
- Avoid tilting or contact between the sensor transmitter and rim.
- Valve bulbs must rest fully against the rim.
- Follow the orientation markings on the transmitter. Incorrect sensor positioning may
result in communication with the RKE Mopar tool but cause improper dynamic
performance.

Figure 1. Location of Markings in the the Tire Pressure sensor indicating correct orientation

Figure 2. Correct the Tire Pressure sensor positioning with orientation markings facing upward.
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC

Version 4.5 07/22/2022

Lubrication
- Apply approved lubricant only to the rubber portion of the valve.
- Avoid contact with the pressure port or the Tire Pressure sensor body.
Tooling
- Use a validated push-in tool with the correct pivot for the rim type.
Insertion Technique
- Align the valve axis with the rim hole.
- Insert the valve straight through the hole—not at an angle.
- Pull the valve rib fully through until the rubber bulb contacts the rim.
- If a push-in tool is not available, use a universal Tire Pressure sensor insertion tool
and follow service procedures.
4. Valve Seating Validation
- Inspect for trapped rubber or incomplete valve rib pull-through.
- Replace damaged valves or those requiring excessive force.
- Add white mark to valve to determine if rotation occurs during Tire Mounting.

5. Tire Mounting for sensor protection
- Mount the tire onto the wheel in accordance with the tire changer manufacturer's
instructions, taking extra care to avoid damaging the the Tire Pressure sensor. Follow
these specific guidelines based on the type of tire changer:
- After securing the wheel to the changer, position the valve stem of the the Tire
Pressure sensor approximately 210° clockwise from the changer head. Then, rotate
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC

Version 4.5 07/22/2022

the wheel clockwise to mount the tire. Apply this method for both the upper and
lower tire beads.
- Place the wheel on the changer so that the Tire Pressure sensor is located about
210° clockwise from the working end of the mounting/dismounting tool. Ensure the
Tire Pressure sensor is clear of the lower bead breaker area to prevent damage when
the breaker rises. Rotate the tool counterclockwise to mount the tire, using this
approach for both the upper and lower beads.
6. Post Tire Mounting Checks
- Check that the white mark previously added to the valve stayed on same position
prior mounting.
- Use standard service procedure to activate and verify the Tire Pressure sensor.
- Confirm RF response with correct ID and pressure.
- Flag for rework if no response or pressure is incorrect.
- Inspect for valve cone damage or misalignment.
- Replace valve if excessive force is needed.
- Check assembly for leaks.

Figure 3. Examples of common damage during tire dismount and sensor insertion.

This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.

Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC

Version 4.5 07/22/2022