What Should You Do if Your DEF is Frozen?
Frozen DEF will not inhibit normal vehicle start-up or operation. Most after-treatment systems have a built-in DEF tank heater that will thaw the fluid during normal vehicle operation. If your vehicle’s SCR has a built-in DEF tank heater, turn the vehicle on to initiate the thawing process. The less frozen DEF you have, the faster it will thaw, so driving with a half or quarter-tank of DEF in colder weather will accelerate thawing.
Your vehicle may display an error code when it detects that the DEF is frozen. Consult your owner’s manual to determine if it’s safe to operate your particular vehicle while the DEF is frozen.
If it’s costing your company money I’d store a box of def inside the house/shop and pour just enough to get the truck to warm up or use some heated blankets and wrap them around the tank or use heat lamps under the truck. Working the oil fields for 25+ years I couldn’t let some freezing def stop me from getting to location because if I don’t make it someone else will.