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DUH!! I don't remember ever getting the DEF 1/2 full warning since the Recall. My truck has always taken 2.5 gallons at half full. Yesterday with the 490 miles warning using a Ford nozzle I couldn't get 2.5 gallons in?? I must be doing something wrong or I have a problem. I would think if I had a sensor problem, the truck would throw a code? I think I'm getting too relaxed after owning a 6.4L
I'm leaving in an hour on a weeks camping vacation and will have to keep my eye on it.
Ya, the def level warnings act very irregularly sometimes. I never got 1/2 full either.
I had never put any def in my truck since it was new, over 6000 miles. At that time, in the beginning of my 'tuning', I installed a H&S MM with all emissions present on the truck. As soon as it was finished flashing the pcm, the 500mile Def warning came on for the first time ever. Shortly after,,, had no need for def.
DEF crystallized very easily. I suspect that many of our errors in the DEF readings or trying to fill, have to do with crystals forming in the tank or line. Often times you will overflow you filler tube with 2 gallons of DEF, But wait a couple of hours and you can put the rest of the jug in after the DEF you added disolves the existing crystals.
I could be totally out in left field, But I don't know why else, I can fill up and then add more later.