Be Aware--DEF Heater Failure

[denandannie]

For those driving Chevy diesels, there is an ongoing problem with DEF heater failures. GMC has extended the warranty on these parts for 10 years. My 2015 Chevy DEF heater failed in year six at 27k miles. Thankfully, the extended warranty saved me about $1000 bucks.

DEF problems are not just a Chevy problem. With all the technology they pack into these trucks, you'd think they would be able to fix this issue.

[Vic B]

It is not only Chev, my Ford F250 had a heater go bad in the DEF tank and it cost me $1000 to replace. I was told the Ford had a habit of failing around 100,000 miles and mine failed at exactly that mileage. Their are two heaters, one small one in the pipe leading to the tank and one in the tank, The pipe heater is a cheaper fix but rarely the problem according to the Ford service manager.

[rohrmann]

Is the extended warranty on the DEF tanks strictly by time or is there also a mileage also? I had to have ours replaced a few years ago and will try to get reimbursed if it’s only by time.

[Mikendebbie]

My 2014 3500 SRW had a tank heater failure Feb. 2019 with 100,400 miles on it. They were not offering extended warranty at that time. I had bought a 100k extended warranty, so I was barely out of warranty and they offered no help. We had been looking for an excuse/justification to buy a dually. DW made the call and we traded it in on the one we have now.

[CaptnJohn]

Neighbor has a 2019 GMC 3500. DEF heater went out at 40 days and took 3 weeks to get the parts to the dealer.

[Dam Worker]

I would think that it should be covered by the Emissions System warranty as it is part of that system. I can also see some Dealerships trying to deny it.

Tom Marty

[Dusters]

My 2015 Chevy 2500HD went out this last fall with 54K for mileage. They ordered the part and kept my vehicle for nearly two weeks because of the holidays. The biggest indicator was the ReGen starts making a lot more smoke and fumes and makes the inside unpleasant. Then one day soon after, I got an engine light. I drove it for another 100 miles off and on but was warned that different stages would start shutting down to the limp mode. They said the technicians would have difficulty getting the codes to clear. I had some issue that didn't go away for several days and they wanted me to pay for a diagnostics. It cleared on its own, thank goodness and Chevy did the work on the extended warranty for this item.

[rohrmann]

When our DEF tank heat coil failed, I took it into the Chevy dealer in Redding, CA, and they had the replacement tank on the shelf. That told me that this was a bigger and more frequent problem than meets the eye. I think it was a bit over $800 for the job.

[GILAELKHUNTER]

The DEF heater went out on my 2016 F-250 at around 40,000 just out of the 36,000 mile warranty, when I called the dealer about it and asked about the emissions warranty they danced around that to no end. They wanted me to bring it in so they could troubleshoot it and diagnostics and said it might be under warranty, but wouldn't know till they did diagnostics. Somehow I think they would have found a way to make me pay for it. I ordered one online and changed it myself for about $100.

[dhuhn]

I’ve. Had two def sensors go out on me both with in a year of each other. Chevy replaced both. They told me it’s a known problem and was covering it even if it’s out of warranty.

[FloridaFiver]

I don't know if it is absolutely correct or not, but some are convinced keeping the DEF tank full of fluid is the real trick to preventing the heaters from burning out early or frequently. The heating element will be operating regardless of fluid level, so an element that may not immersed in fluid would be expected to be operating at a significantly higher operating temperature than one that may be submerged in a full tank. Seems logical to me. We try to keep our DEF tank as full as possible in case this may be true.

[Dave from GR]

We have a 2011 GMC and DEF issues are common on all makes of trucks for years according to my mechanic. Is your 2019 easy to top off your tank or do you fill until you spill, like my2011?

[Dave W]

2011-early 2015 Fords have an extended warranty on DEF heaters - 125K or, IIRC, 10 years. Mine was replaced at 124750 miles at no cost plus the completely refilled the almost empty DEF tank. Took them about 3 hours with an oil and filter change thrown inthat time (my cost). The heater is fairly inexpensive but they hurt you on labor. I bought and still have a spare heater', bought a couple weeks before the Ford letter arrived - and it can be purchased cheap if a DIYer if you PM me

[twindman]

I think maybe the heaters are temperature controlled. Since I live in AZ year round, our winters rarely get below freezing so I don't think my heater ever runs!! I have had no problems with that. However a couple of sensors with the DEF went out at around 50,000 miles and was replaced for free (including the tank). I have 3 letters in the glove box that says various things are extended to 10 years and 120,000 miles - all emission related.
That didn't help last fall when I forked out $2500 for exhaust sensors and a computer board tho. (100K miles on it now)

[Rondo]

We had a 2012 3500 HD and it cost us over $4000 to replace the total exhaust system because that was ordered by the GM engineers because the dealer we had it at could not figure out why the problem was happening. It went into the dealer we bought it from after four months and they replaced two of the sensors in the DEF system. At about 40,000 miles it happened again and again under warranty. The next year, while in AZ it happened again and that's when the $4000 came into effect and it was out of warranty then and the dealer kept the truck for a month trying to figure what was wrong. Before heading for AZ the next year the DW decided it was time for a new truck so we bought one and since then no problems. The 2018 unit has been good SO FAR and I was told by the local dealer NOT TO FILL THE DEF tank all the way full. It has a 7 1/2 gallon tank on it and to only put 5 gallons at the most into the tank and run it that way. Also talked to a GM area rep while down in AZ and asked him about it and he said the same think so "knock on wood" things have and will be going good from this point on.

[Coronabob]

We had a failure on our 2017 GMC. We were on our way to pickup our new Montana and got a warning on the dash. Continued onto pickup the Montana. We had a res for the night (we wanted enough time to do the PDI.). Took to a dealership in Grants Pass Or. They were excellent, got me in right away. Had to order parts, wrong part came in. ETC, ETC.
At least we spent 5 days in the new Montana at the RV Park and sorted a ton of stuff out.
I haven't been happy with the whole emission system on this newer truck. My 2009 GMC never had a hiccup.

[mhs4771]

Rondo, I do just about the same. When the warning comes on telling me I have X amount of miles (generally 200 to 300 miles) I'll dump in 5 gals and be on my way

[Dave10]

I believe Ford, GM, and Ram use many of the emission parts from the same vendor. Ford extended their warranty on DEF and several probs and I suspect GM and RAM have done the same. Most dealers should help if you contact them in a civil manner.

[Twopetes]

Just had the DEF heater on my 2011 F-250 replaced under warranty. Also had the exhaust sensors replaced under warranty. service bulletin- 18M01 and 15M02. My 250 has 110000 miles. Warranty was extended to 120000 miles and 10 years. Has to be done by a Ford dealer. Only covers certain years and models.

[CADman_KS]

Originally Posted by Dam Worker

I would think that it should be covered by the Emissions System warranty as it is part of that system. I can also see some Dealerships trying to deny it.

Tom Marty

It sure seems like it should be covered under warranty, but I know when we had our VW Touareg, the heater was not covered under warranty. In fact, nothing really associated with the DEF system was covered under any type of long term emissions warranty. Take that with a whole BLOCK of salt, because they are the ones that got caught cheating on diesel emissions, so not the best place to look for answers.

I don't care who the manufacturer is, it seems like a stretch to say that the DEF SYSTEM is not covered under emissions warranty. If I take it off, am I in violation of the EPA standard? Uh yes. If it's not working, because the heater went out, is that my fault or the manufacturers? I didn't make the heater quit working. While I don't want more legislation, it seems like the consumer is the one rolling the dice on this stuff, especially when we as consumers are regulated on what we CAN'T do to the system. Should work all the time then...