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Def does start to freeze at around 12 degrees Fahrenheit so it is very possible that depending on the weather conditions and time between drive cycles that it can freeze.Def shouldn't freeze no matter how cold is, it's the heater who's not doing the job.
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The heater though should have no problem thawing it back out. Try to take a longer than usual trip to give the heater more time, and see if that makes any difference.
Generally DEF usage is related to fuel usage, so if your fuel usage is going up then chances are your def usage is going up also. To determine whether you think the percentage reading is correct though will involve crunching some numbers.
When you say you poured in a big jug, did you actually see the level up at the top of the tank or just pour in what you had? Usually when I fill mine up it takes almost 5 gallons from empty.