Maybe this is hit-or-miss because I have used several K&Ns over the years on several vehicles without problems. I've even ran UOAs on a couple of them with no problems found. Before BITOG I ran a K&N on every vehicle. After BITOG I have really taken a look at MPG and UOA of my vehicles with and without K&N and determined that my "every-day" vehicles do not need a K&N and do not gain (any noticable) MPG with one. However, the vehicles that I am trying to get extra HP and better throttle response from are still getting the K&N. I tried the old Amsoil foam filter on one vehicle and MPG went into the toilet. I am now running the new EAA filter on one vehicle that I just bought last month and only have two fuel tanks to compare, one pre-EAA and one post-EAA and am happy to report that the mileage slightly improved, however I cannot atribute that solely to the EAA since I performed a lot of maintenance services during the time period. I am just happy that the mileage didn't go down like it did when I used the foam filter on another vehicle.
Maybe I have just been lucky with my K&Ns and others haven't but the two vehicles that I did a UOA on had low wear and low silicon levels. Perhaps K&N is outsourcing some of their manufacture or their QC is not good on some product lines. The "drop-in" type filters that I normally use have never had quality issues.
One thing about the MAF; I believe that the sensors are becoming more and more sensitive through the years and incidents of MAF fouling are becoming more common. I have in my possesion a letter from K&N about the testing that they do of failed MAF sensors, signed by Arleen Priutt, Consumer Relations, Dated August 27, 2007, as follows: "Silicone is used in mass air flow sensors to insulate the electronic circuit board from moisture and vibration. Experience has shown that most repair shops are not aware of the silicone gel used in MAF sensors and therefore, are unable to conclude that a sensor may be contaminating itself. Because of this lack of information, unfortunately for us, some repair shops immediately conclude that it is K&N's aftermarket filter that contaminates MAF sensors." and further, "K&N's independent extensive testing has found no instances where its filter oil has ever contaminated a mass air flow sensor."
I have seen that K&N rigorously defends their product but I've also seen manufacturers putting bulletins out about MAF sensor fouling from using oiled air filters. For me, I am still willing to take a chance if I am trying to squeeze power and throttle response out of an engine, but otherwise I'd rather avoid any possible headaches down the road and just use plain paper or an Amsoil EAA.