It doesn't need to freeze solid for the system to become inoperable. It is more common for it to freeze and become a problem on pickups than big trucks for sure, whether that is tank size or tank placement I'm really not sure. Seeing as how the GMs seem to be the worst for freezing tanks, I'm guessing its placement.
I have not as of yet diagnosed and repaired any DEF systems, the parts are expensive and typically by the time people call me the dealer has run them thru the ringer for so much they are just fed up and want the equipment gone.