In a new John Deere 5105 ML I had the dealer bill me for what I thought was warranty work, because they claimed the Def in the tractor was out of spec. I use the same def in two Cummins engines and one Cat engine and never have had any issues. The 5105 Ml only has about 300 hours and I purchased an extended 5 year warranty. A 781.00 bill to drain out the def and replace it. They also changed out the exhaust gas cooler which they did cover under warranty. Could the def be bad in just that one engine when it is running fine in the other engines? I have never had problems with Def before. Has anyone had problems with def?
The only problems we've ever experienced with DEF were operator induced. Def "Systems", sure. It's a mechanical thing like any other, and every now and again it'll ask for a part, but overall they're pretty reliable.
I'm not familiar with John Deere, as we've avoided them (mostly) simply due to their unwilllingness to allow us to look after our own machines. But modern after-treatment isn't entirely rocket surgery. You might or might not like anything I can come up with having one hand tied behind my back (no idea how they implement or monitor the system...)
First though, yes, DEF can go bad, and the time isn't really relevant. Poorly stored, it can be dead in no time at all. Chemical contamination is instant. Concentration can be off, but that takes time. In practice, if it's kept clean and stored well, it'll almost always outlast it's shelf life. (no guarantees, but almost always).
Did the dealer or any of your paperwork say or imply exactly what method they used to determine the DEF was bad?
Can I assume that "exhaust cooler" is actually the "EGR cooler? If that is the case, than I've got questions I won't be able to answer....
If indeed the DEF did need changing, "most" DEF filler necks can either have their filter/strainer pulled out to allow pumping it out, or they have a drain to drain it out, or they have a scan tool function to pump it out of one line or another using the onboard equpment. But it's John Deere, so maybe they don't... But I have a hard time with that price. The time, the replacement fluid, and disposal, which is generally tossed under the hazardous disposal fee, because although DEF isn't hazmat, it takes all the same steps and all the same costs, and all the same headaches to dispose of it. That's three or four hours... You can do a bunch in three or four hours. But you're on (what appears to be) a very specialized tractor, and specialized machines tend to have compromises in serviceability to get the specialty features built in. Maybe the shape/size/profile makes cramped access? I guess I have a hard time with that price, but at the same time it is NOT high enough to raise a red flag in and of it's self, without knowing more than I do.
What did the tractor actually go in for? What was your specific complaint?