One common reason a gas furnace might be taken out of service is due to a cracked heat exchanger. The heat exchanger is a crucial component in your gas furnace, transferring heat from the gas burner to the warm air blown into your home. When it fails, it poses significant dangers, including the risk of carbon monoxide poisoning. Additionally, replacing a heat exchanger can be costly, often making it one of the more expensive furnace repairs.
In this article, we’ll discuss how difficult it is to replace a heat exchanger and whether it’s worth the cost, considering the age of your furnace, the price of a new heat exchanger, and the labor involved in installing it. In many cases, replacing the entire furnace may be more cost-effective than just replacing the heat exchanger.
Dangers of a Cracked Heat Exchanger
Using a furnace with a cracked heat exchanger is extremely dangerous. Large cracks or holes can release carbon monoxide (CO) into your home, which can be deadly. Safety should always be your priority. It’s essential to understand that while CO isn’t caused by a crack in the heat exchanger, the cracks can release CO from unburned fuel into your living space. These cracks won’t improve over time and will eventually require replacement.
Most HVAC contractors will “red-tag” a furnace with a cracked heat exchanger, which involves disconnecting the power and gas and reporting it to the gas company. This ensures safety but can also leave you without heat until the issue is resolved. However, be cautious of contractors using this as a pressure tactic to sell a new furnace.
Always get a second opinion from another professional before making any decisions.
Why You Can’t Repair a Cracked Heat Exchanger?
It’s not a good idea to try to fix a cracked heat exchanger because there’s no guarantee the repair will hold. This could lead to another carbon monoxide leak, which is really dangerous.
The crack usually happens because of stress from changing temperatures, and trying to seal it may not work because the whole part is damaged. If the fix doesn’t hold, the crack could get even worse. This poses a risk in case of a carbon monoxide leak, as there would be even less time to deal with the dangerous gas buildup in the house.
Heat Exchanger Replacement Versus Repair
If you find out you need to pay around $1500 for labor to replace the heat exchanger, it might be worth considering a new furnace. Often, for a bit more money, you can install a new, more efficient furnace that provides better long-term value and might qualify for tax credits.
When to Consider Repairing the Heat Exchanger:
- If your furnace is less than 10 years old
- If the heat exchanger is fully covered by the manufacturer’s warranty
- If the repair cost is less than 25% of the cost of a new furnace
When to Replace the Furnace:
- If your furnace is more than 10 years old
- If your furnace is low-efficiency
- If the damage is extensive
- If you have already received at least two-second opinions confirming the issue
Many gas furnace brands offer a lifetime warranty on the heat exchanger. This typically covers the cost of the part itself and may include other necessary components for the replacement. However, the labor costs to disassemble and reassemble the furnace can be significant.
Even with the part covered under warranty, you may still face high labor costs, and after the replacement, you’ll still have an older furnace prone to other issues.
Conclusion
Deciding whether to repair or replace a furnace with a cracked heat exchanger involves considering the furnace’s age, efficiency, and the total cost of repairs versus replacement. While repairing might seem cheaper initially, the long-term benefits of a new, efficient furnace can outweigh the costs. Always seek multiple opinions and ensure you’re fully informed before making a decision.
Have you recently faced a cracked heat exchanger or had your furnace red-tagged? Did you opt for repair or replacement? Sharing your experience can help others in similar situations make informed decisions. Feel free to share your story and insights below.
