Can a cracked furnace be repaired?

Author: Billy Hermiston  |  Last update: Thursday, March 20, 2025

Can a cracked furnace be repaired so you no longer have to live with this risk? Yes, repairs are possible and must happen immediately for your safety.

Is it safe to run a furnace with a cracked heat exchanger?

So, can you run a furnace with a cracked heat exchanger? The straightforward answer is no. Operating a furnace under these conditions is unsafe and can lead to severe consequences, including the risk of carbon monoxide poisoning.

How much does it cost to fix a cracked furnace heat exchanger?

It can range between $1,000-$4,000 for parts and labor, with an average cost of $2,000. Learn how this heat exchanger cost breaks down and how to identify the crucial signs it's cracked and needs replacement.

What is the most expensive part to fix on a furnace?

A heat exchanger replacement is often one of the most costly repairs in a furnace, and the expense can sometimes rival that of installing a new furnace. Typical replacement costs vary widely but can easily reach several thousand dollars, especially if labor costs are factored in.

Is it worth fixing a furnace?

While furnaces can last longer with proper maintenance, they often become less efficient and more prone to breakdowns as they age. Repairing a 15-year-old furnace can provide a temporary solution, but it may be a better long-term investment to consider replacing it.

Watching A Furnace Run With A Cracked Heat Exchanger

What is the average cost of a furnace repair?

Furnace repair costs $317 on average. The cost depends on furnace type, which part needs repair, and contractor labor rates in your area, so the final price will range from $132 to $501. A cozy night in can quickly turn sour if your furnace decides to break down.

What is the life expectancy of a furnace?

Life Expectancy of Common Heating Systems

Furnaces: 15-30 years. Boilers: 15-30 years. Heat Pumps: 15 years. Active Solar Heating: 20+ years.

Does insurance cover furnace failure?

While there's no such thing as furnace or boiler replacement insurance, homeowners insurance may cover the cost to replace your furnace or boiler if it's damaged or destroyed by a covered peril.

How long does it take to fix a broken furnace?

Most regular furnace repairs take between 1-4 hours to complete, but for some, it can take much longer. Simple problems like replacing a thermostat or ignitor may only take a qualified professional 30-60 minutes.

What is a common failure for a furnace?

One of the most common furnace problems is a malfunctioning thermostat. A sure sign your thermostat isn't working properly is if your fan is constantly running. This will cause your thermostat battery to run, and cause your furnace to work inefficiently.

What are signs of a cracked heat exchanger?

Signs Your Heat Exchanger May Be Cracked
  • Strange Smells. When your furnace kicks on, you may notice a dusty odor as the air first moves through the ducts and vents. ...
  • Soot Buildup. ...
  • Corrosion. ...
  • Flame Appearance. ...
  • Recurring Flu Symptoms. ...
  • Furnace Won't Work. ...
  • Carbon Monoxide Detectors Keep Going Off.

What is the most reliable gas furnace brand?

The 5 Best Furnace Brands
  • Carrier Furnace: Best Warranty.
  • Lennox Furnace: Best Company Reputation.
  • Bryant Furnace: Best for Durability.
  • Trane Furnace: Most Years of Experience.
  • Amana Furnace: Best for Efficiency.

Is it better to replace a heat exchanger or a new furnace?

Furnaces have an average lifespan of around 10 years, and most exchangers tend to go out around this time. If your furnace is close to this 10-year mark, a new furnace is likely a better investment. If your furnace is relatively new, a new heat exchanger may be worth it to avoid early furnace replacement.

How to fix a cracked furnace heat exchanger?

Repairing a heat exchanger involves welding the cracks or applying heat-resistant epoxy. However, due to the critical role the heat exchanger plays in a furnace, ensuring the integrity and safety of the repair is paramount.

Can you smell a cracked heat exchanger?

Soot can collect when combustion is incomplete. This can be caused by burners that are improperly adjusted or a cracked heat exchanger. A faulty heat exchanger will produce a strong and unpleasant odor that smells similar to formaldehyde.

What causes cracks in the furnace?

An overheating furnace causes nearly all premature heat exchanger cracks. When a furnace cannot get enough airflow, the heat exchanger overheats and suffers excess stress from expansion and contraction. Over time, the heat stress causes cracks near weak areas such as bends or welds.

How do you heat a house with a broken furnace?

6 Ways to Creatively Heat Your House If Your Furnace Broke
  1. Dress in Layers. Your first step when you're trying to stay warm should be to preserve as much of your body heat as possible. ...
  2. Section Off the House. ...
  3. Use Your Oven. ...
  4. Use Hot Water. ...
  5. Space Heaters. ...
  6. Fireplaces.

Should I repair or replace my 12 year old furnace?

The age of your system is the first factor to consider. The average lifespan of a furnace is 15-20 years; after that the system will start to fail more often. If your furnace is 10 years old or less, repairs should be effective. If it has reached 12 years or more, it's time to consider replacement.

Can I fix my furnace myself?

Can I Fix My Furnace Myself? Yes, simple tasks like changing the air filter or resetting the circuit breaker are safe DIY options. For complex issues, consult a licensed HVAC professional.

Does State Farm homeowners insurance cover furnaces?

Does homeowners insurance cover a furnace? A furnace isn't covered for normal wear and tear or replacement. This is considered to be part of your typical home maintenance. However, you may contact your local State Farm® agent for information on Home Systems Protection.

How much does a new furnace cost?

You should expect to spend between $3,800 and $12,00 on a new furnace, including both the unit and installation costs. Factors influencing the price include the type of furnace (gas, electric, or oil), the unit's efficiency rating, and the complexity of the installation.

How do you diagnose a broken furnace?

Furnace Troubleshooting Steps
  1. Air filter should be clean and properly installed.
  2. Make sure power is on at the breaker box and disconnect switches. ...
  3. Check the thermostat for proper location and setting (“heat”). ...
  4. Check the pilot light. ...
  5. Gas valve should be “on” (parallel with the pipe).

Should I repair or replace my furnace?

Repair: If your furnace system is less than 15 years old and the cost of repair is less than half the cost of replacement. Replace: If your furnace system is more than 15 years old and requires a costly repair to maintain efficiency.

How many hours does it take to replace a furnace?

If you're worried about not having heat while the installation is in progress, the good news is that most replacements won't take more than a day. On average, home heating companies can complete the installation in about four to eight hours, depending on the size of your house.

At what age should a furnace be replaced?

The typical lifespan of a furnace can be anywhere from 15 to 30 years. If you've had your furnace for less than 15 years, you likely don't have to worry about replacing it any time soon. But if it's older than 15 years and you've started noticing problems, it may be on its last leg.

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