There are some issues with your HVAC system and furnace that aren’t as amenable to repairs, One of those is a cracked heat exchanger.
Unless your system is still under warranty, a cracked heat exchanger means you should replace your whole furnace– it’s a safety issue, and it’s a cost issue.
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What is a Heat Exchanger?
A heat exchanger is the important part of your furnace where the combusted fuel- often gas or oil- is contained. It can look like the picture below- usually a series of coils, loops and plates made out of metal.
Air is blown across the heated metal and then distributed around your home- but the heat exchanger is where the “business” of heating occurs.
As a result of repeated cycles of heating and cooling, the metal expands and contracts. Over time, the metal eventually becomes brittle and can develop tiny holes and cracks due to metal fatigue.
This means the combusted fuel gas- and carbon monoxide- can seep into your home and cause a problem.
One of the issues with heat exchangers is that they are hard to get to in your furnace, – they are labor -intensive to get to, and it’s difficult to detect small, pinpoint holes.
Once a heat exchanger is cracked, it can be 8- 10 hours of labor plus the part itself is often in excess of $1,000, meaning you can be looking at a repair of $3,000 or more.
Cracks in the heat exchanger are a sign of serious wear and tear on all parts in your furnace, One repair often leads to additional repairs being needed on the furnace.
It rapidly becomes a very expensive proposition, where it becomes more cost-effective to replace the whole furnace than repair.
But It’s Still Less Than Replacement, So Why Not?
While you certainly could replace the heat exchanger, one of the other issues to consider when facing a big expense like this is whether upgrading to a new system would be more cost-effective in the long run.
The truth is with systems that are currently 15-20 years old, newer systems with electronic ignition, no pilots, and other efficiencies can end up saving you a LOT of money on monthly energy bills.
An older, less efficient furnace may still end up burning more fuel and cost you more each month than a new system will.
There are also rebates and new tax incentives coming in 2023 for people adopting higher-energy efficient systems for their homes.
Energy companies and the federal government are putting incentives in place to help homeowners make the switch to greener home heating solutions.
That includes electric heat pump systems, which can be up to 70% more efficient for heating for your home.
Getting The Right Sized System- And Zoning
If you have any hot or cold spots in your home- many people do, especially if you live in a split level or contemporary styled-home- a new HVAC system and furnace is also an opportunity to get a new system that is properly sized.
Your local HVAC professional can do something called a load calculation and figure out what size furnace you need to make your home comfortable throughout.
The new system can even be designed with zones, so you can keep the areas of your home in most use comfortable, while not spending money heating and cooling areas when you’re not there.
Some of the newer heat pump systems can be fitted with motion detectors as well, so the system automatically comes on or shuts off depending on whether or not the room is occupied.
The Bottom Line
Unfortunately, if you have a cracked heat exchanger, you are looking at a very dangerous situation that needs an immediate solution for your health and safety.
While it is possible to replace a cracked heat exchanger, it’s rarely cost-effective in the long run on a furnace that is out of warranty, as you are looking at substantial parts and labor costs.
Replacing the whole furnace can take half as much time, and will give you 15-20 years of expected use before needing replacement.
That’s why most HVAC contractors will counsel you to look at replacing your whole furnace if you have a cracked heat exchanger.