Freightliner and DEF Sensor Failures

[Butte64]

At an AIM rally Robert from Freightliner said they have resolved the DEF sensor failure that has been affecting so many people. Since Spartan uses sensors made by Shaw I asked about the source that FL uses. He said he would let me know but it has been more than a week and no answer. So a few questions for FL owners.
- Does everyone agree that FL has resolved the DEF sensor problem?
- who makes the sensor used by FL?
- when a DEF sensor problem occurs on a FL system, does anyone know how far you can go before derate and shutdown? This is a critical safety problem because it leaves people stranded on the side of the road.

[R.Wold]

Originally Posted by Butte64

At an AIM rally Robert from Freightliner said they have resolved the DEF sensor failure that has been affecting so many people. Since Spartan uses sensors made by Shaw I asked about the source that FL uses. He said he would let me know but it has been more than a week and no answer. So a few questions for FL owners.
- Does everyone agree that FL has resolved the DEF sensor problem?
Knocking on wood, but the third DEF header on this coach now has about 8,000 miles since Jan. of this year with no codes, MILs, or apparent issues. This is good news if it is truly resolved - I’m too superstitious and gun-shy to make that statement
- who makes the sensor used by FL?
Never found out either
- when a DEF sensor problem occurs on a FL system, does anyone know how far you can go before derate and shutdown? This is a critical safety problem because it leaves people stranded on the side of the road.

Well this is subjective, but if you don’t shut off your engine until you reach your destination you can probably go as far as you need to - I’ve been told by several FL techs it’s based in “ignition cycles” (although diesel doesn’t ignite...) but at some point it will probably start the derate process anyway.

Also once derate is initiated, it occurs in stages of 25% power reduction, down to the dreaded 5%. So you might not even notice the initial derate unless you are towing or climbing grades - which is why you need a code reader (or or if driving a Freightliner, at least learn to manipulate the LBCU) to confirm and plan your strategy if you get the “check engine” light.

[kpecks]

I’m reading this thread as we sit in Fort Smith Arkansas as we wait for the freightliner shop to determine the course of action they’re going to take to fix the 5 error codes related to the DEF system sensor... what I can tell you is I drove over 200 miles with the CEL on.... the dash warning eventually went from “low DEF” to “Very low DEF”. The odd thing is I filled up the DEF two fuel stops ago and had no issues until we got 2 miles to the next fuel stop.

We have a 2017 Dutch star 4310.

[kpecks]

Originally Posted by kpecks

I’m reading this thread as we sit in Fort Smith Arkansas as we wait for the freightliner shop to determine the course of action they’re going to take to fix the 5 error codes related to the DEF system sensor... what I can tell you is I drove over 200 miles with the CEL on.... the dash warning eventually went from “low DEF” to “Very low DEF”. The odd thing is I filled up the DEF two fuel stops ago and had no issues until we got 2 miles to the next fuel stop.

We have a 2017 Dutch star 4310.

Annnnd $3000 later, I’m hoping to have a new DEF head overnighted and installed tomorrow or Monday the latest....

[R.Wold]

Originally Posted by kpecks

Annnnd $3000 later, I’m hoping to have a new DEF head overnighted and installed tomorrow or Monday the latest....

Why $3000? Unless you are over 100,000 miles, your emission warranty (5 hrs, 100k miles)is current. I had a new DEF header replaced under warranty this year on my 2016 by the Sacramento Freightliner shop.

[kpecks]

Originally Posted by R.Wold

Why $3000? Unless you are over 100,000 miles, your emission warranty (5 hrs, 100k miles)is current. I had a new DEF header replaced under warranty this year on my 2016 by the Sacramento Freightliner shop.

I just spent 20 minutes on the phone with freightliner and, sure enough, it is covered. Went back to the service center and they fixed the “glitch” in their system... so it’s all covered under the 5yr/100k emissions warranty...

[R.Wold]

Originally Posted by kpecks

I just spent 20 minutes on the phone with freightliner and, sure enough, it is covered. Went back to the service center and they fixed the “glitch” in their system... so it’s all covered under the 5yr/100k emissions warranty...

Glad to hear it! Guess you can disregard the PMs...

[R.Wold]

So I’m curious whether or not it’s the same part number (A04-28402) or a new gen like Spartan/Shaw

Also it’s a $900 part and takes less than an hour to change, so their estimate was either way off or for more than the header unit. This shop sounds like it may be a little shady....

[kpecks]

303F/04-35163-000 HEADER DEF,15G,SSI,DEAERATE is what was ordered. Definitely seems a bit sketchy on the labor charges of nearly $1322 for the repair but at this point, I’m happy it’s all under warranty!

[Tankd]

I'll get into the ball game here. I replaced our DEF header a few weeks ago. Not the same as most, but it still failed. This one would always read empty, no matter what. The check engine light would come on when it was getting low. I'd pull over and put in a few gallons and off we go again. Finally got tired of it and replaced it. Drained, removed the tank and replaced the header. The local Freightliner had one in stock. Went over and they was nice enough to let me check the ohms on the counter before I bought it. Replaced and all worked as it should. Now, see how long it lasts.
--John--

[kpecks]

I’m still stuck in FT. smith Arkansas over Memorial Day weekend because the stupid shop didn’t expedite the part!!! Unreal. I’d do it myself if I could find the part but there is nothing within 8hr drive!!

[R.Wold]

Originally Posted by kpecks

I’m still stuck in FT. smith Arkansas over Memorial Day weekend because the stupid shop didn’t expedite the part!!! Unreal. I’d do it myself if I could find the part but there is nothing within 8hr drive!!

Well at least you’re not getting robbed. That estimate still really bugs me. There is so much wrong with it. Do they tax labor in Arkansas? If not what’s with the 10.26% tax? And $145 for misc? What the heck is that? Hose clamps? B. S. ! And of course since it’s about an hour job, it really makes you wonder about their labor rate - $1300/hour?????

Anyway, I spent Thanksgiving last year at Velocity Truck in Las Vegas. Improvised an unplanned thanksgiving dinner with what we had on hand because we limped back Wednesday night after their first repair failed, and of course they couldn’t get back on it until Friday. At least they had 50amp service for us. Then on our next trip we had to abandon a multi-family holiday camp out and turn back on Christmas Day for another DEF issue - that time it was the pump.

So while it’s no compensation, at least you aren’t the only one with holiday plans torpedoed by this faulty, poorly engineered, misguided emissions system. Guess I’m ranting again.....

[vettenuts]

Originally Posted by Tankd

I'll get into the ball game here. I replaced our DEF header a few weeks ago. Not the same as most, but it still failed. This one would always read empty, no matter what. The check engine light would come on when it was getting low. I'd pull over and put in a few gallons and off we go again. Finally got tired of it and replaced it. Drained, removed the tank and replaced the header. The local Freightliner had one in stock. Went over and they was nice enough to let me check the ohms on the counter before I bought it. Replaced and all worked as it should. Now, see how long it lasts.
--John--

What year is your coach?

[DerekF]

We’re sitting at a FL service center north of Denver with DEF sensor error codes. Part was ordered 5/14 and still no ETA. If no news tomorrow I’ll call Cummins. Looks like we won’t make our June 7 appointment at Fleetwood in Ind. Coach built December 2020, we bought beginning of February. Only has 3300 miles.
Worst part is can’t make any plans.