I'm having a situation that appears to be a bad sensor as well. Last time I got a low def alert I put some in it but it overflowed after half of one of the Blue DEF jugs. Since I got it back from the 7500 service it has been acting hokey. On the way home from town yesterday I had it register low and then empty but within a couple miles it registered almost full again. The truck drives fine other than that so I'd say the sensor has to be out of whack.