Just a follow up.
This started for me on 7-14-18. My DEF level sensor failed somewhere between 69,000 - 79,800 miles. The DEF level sensor is molded into the DEF tank and if it fails, you need a new DEF tank, if you are required by vehicle smog testing to keep all of the emissions in tack.
I ended up replacing the DEF Tank after trying for almost 6 weeks to get FCA to pay for based on the fact that my truck is registered and licensed in the state of Utah in a county where I need to get emissions test. Under federal emissions up until 80K miles, all components are covered if the vehicle is registered in a place where emissions test are required and you need to pass that test in order to get registration and or tabs.
I am still not through with FCA and will be talking to them again on Monday. But I got tired of there BS and having to start my truck with a wire every time I need to drive somewhere.
During the process I visited 2 different RAM dealerships and talked to them about the issues. Each time, they plugged it in and tried to reset codes. One dealership said the level sensor was possibly bad. If not that, then the PCM. They wanted to charge me $2,600.00 for the DEF tank. The other dealership told me only the DEF pump was bad and they wanted $1,500.00 for a new DEF pump.
The codes where the same for each dealer, they both had WiTech micropod II's that where linked to WiTech software.
How 2 different trained and certified techs came to 2 different conclusions while using the same tools is one of the things I am talking to FCA about. That should not happen.
What I ended up doing to troubleshoot on my own time is get a 3 day subscription to Tech Authority. This is the same resource that FCA engineers and Dealer techs have.
TechAuthority
I read up on the MIL codes and learned just how intuitive it was to follow the workflow and logic in trouble shooting a issue. It is simple. Most folks should be able to do this. Certainly, a factory trained technician. Even level 3's.
Next I purchased a copy of AppCar software and installed it on a windows 10 laptop. Within the PCM module, there is a diagnostic interface to see live data. I interfaced my LX code scanner to the OBDI II port of my truck and paired it with my software and laptop. I went into the PCM module and selected the UREA system analysis where I could see real time info on voltage, volume in mm, temperature and concentration. The only parameter I could get in real time was temp. The others where reading 0.00. Using my 3 day Tech Authority I could look at schematics and see that the temperature data is coming from a different wiring harness. So that made me suspicious of the other four wire connector which attaches to the DEF pump.
Next I looked for those part numbers on TechAuthority and found them. Next I googled the part numbers. I got multiple hits for the part numbers. The official Mopar site is the most expensive. Often 50% more in cost than the 30 or so authorized Mopar online parts shops. The same OEM parts at different price levels. Go figure!
Clicking in the return hits on google I also found new OEM parts on eBay at almost 1/10th the cost of the official Mopar site.
https://www.ebay.com/itm/DEF-Pump-E...okee-Ram-and-Promaster-14-16-NEW-OEM/253825959935?_trksid=p2485497.m4902.l9144F
Still I was feeling ripped off. I mean, this thing did not even last past 80K. How in the world did this part even make it out of review? FCA knew this part could fail at anytime? Yet, they still chose to release it and go into production with it.
Next I remembered somewhere here in another thread mention
Car-Part.com--Used Auto Parts Market for used parts. I went there and entered into the search area what I was looking for. I found a DEF tank and DEF pump out of the same wrecked 2015 eco D with 26K miles about 1 hour away. I called the auto salvaged yard that had it listed and they wanted $350.00 for the DEF tank and another $300.00 for the DEF pump. I continued to look at the results from my query on car-part.com and found a 2016 eco D with 21K miles in Oklahoma. They wanted $300.00 for the DEF tank and DEF pump combined. For another $50.00 they shipped it to me UPS and I had it within 5 business days.
I just got it installed yesterday after work. It took me about a hour. The first thing I did was pull the DEF pump on my truck and put the DEF pump from the wreck on it. Using my laptop with AppCar, I went back into the PCM module and checked the UREA section to see what values I was getting. Nothing new, it was the same as my values in my DEF pump. So that told me that perhaps it was the DEF level sensor in my tank. So I put the new to me DEF tank in and the DEF pump that came with it back in. Put all the connectors back together and wrenched the tank in, put back my skip plates and cross support. Then I cleared the codes, looked at my UREA section in the AppCar software and saw a value for level in mm, urea concentration and voltage.
Man I was happy. I put the starter relay back in and started my truck with a key fob (the first time in 6 weeks) and then test drove my truck. I got about 4 miles and cel came back on with the same message, that I needed to see dealer to have my DEF system serviced. Once I got home, I reset the codes again. Turned off my truck and went inside the house for a beer. After beer, I went back out to see if it would start. It did. Great. More beer and some sleep was in order. So that is what I did. Today, I drove it about 60 miles on the interstate and all codes remained off.
Problem solved. But FCA is not off the hook. I still have a bone to pick with them.
Now, I still have my original DEF tank and DEF pump. I will keep the pump, as I might need one of those again. Perhaps. We will see. Regarding the tank, I was thinking about cutting a hole in the top and yanking out that DEF level sensor to see if I can find out who is responsible for the POS design so I know who to bitch at later. Unless someone here has a better idea, that is what I will do.
View attachment 74576
My old DEF tank with removed DEF pump.
