Cracked Heat Exchangers
Cracked Heat Exchangers | Heat Repair | Heating and Air Conditioning | Kodak
When the chill settles over Kodak, a cracked heat exchanger can turn your cozy retreat into a safety hazard within minutes. HEP’s seasoned technicians specialize in fast, meticulous heat repair that restores warmth while protecting your family from carbon-monoxide risks. We pinpoint fractures, corrosion, and ventilation problems with advanced diagnostics, then rebuild or replace components to factory specs—all without the upsell pressure you dread.
Customers across Sevier County count on our no-surprise pricing, same-day responses, and tidy workmanship. Whether your system is gas, electric, or hybrid, we stock the right parts on our trucks to finish most jobs in one visit, and we back every repair with a satisfaction guarantee. When your furnace sputters or your utility bill spikes, call HEP for crack-free comfort that lasts.
FAQs
What is a heat exchanger and why does it crack?
In a gas-fired furnace, the heat exchanger is a sealed metal chamber or series of tubes that separate the hot combustion gases from the household air flowing through your ductwork. Over years of thermal cycling—repeated heating and cooling—the metal expands and contracts. Factors such as poor airflow, an oversized furnace, inadequate maintenance, or corrosion from moisture can accelerate this fatigue, eventually causing the metal to split or crack.
Why is a cracked heat exchanger dangerous?
A crack allows combustion by-products such as carbon monoxide (CO), nitrogen dioxide, and sulfur dioxide to mix with the indoor air you breathe. Even small amounts of CO can cause headaches, dizziness, or nausea, and higher concentrations can be lethal. In addition, the furnace may burn less efficiently, overheat other components, and pose a fire risk. For these reasons, most manufacturers and safety codes require a furnace with a cracked exchanger to be shut down until repaired or replaced.
What warning signs indicate my heat exchanger might be cracked?
Common indicators include: (1) soot or scorch marks on the furnace cabinet, burners, or vent pipes; (2) a strong, persistent chemical or formaldehyde-like odor when the heat runs; (3) frequent or unexplained tripping of the flame-rollout or high-limit switch; (4) visible rust flakes or corrosion on the exchanger surface; (5) unusual flame behavior—yellow, wavering flames that jump when the blower turns on; and (6) physical symptoms such as headaches or nausea that improve when you leave the house. If you notice any of these, schedule an inspection immediately.
How do you confirm a cracked heat exchanger during a service call in Kodak?
Our certified technicians start with a visual inspection using mirrors, borescopes, and high-intensity lights to look for surface cracks and pinholes. We follow up with combustion analysis, measuring CO levels in the supply air and flue gases. Pressure or smoke tests may also be performed to detect leaks. We document findings with photos or video so you can see the damage yourself before deciding on the next step.
Can a cracked heat exchanger be repaired, or do I need a new furnace?
Because the heat exchanger is a critical safety component, most manufacturers prohibit welding or patching. If the furnace is under heat-exchanger warranty, the part may be replaced, but labor costs can still be significant because the job often requires removing major sections of the furnace. If the unit is more than 10–15 years old or out of warranty, replacement of the entire furnace is usually more cost-effective, provides higher efficiency, and restores full warranty coverage.
How quickly can you replace a furnace with a cracked heat exchanger in the Kodak area, and what will it cost?
For emergencies, we can have a replacement furnace installed within 24–48 hours, weather and parts availability permitting. Cost varies by furnace size, efficiency (80% vs. 95+% AFUE), and any duct or vent modifications required. In Kodak, most standard gas furnace replacements range from $3,500 to $6,500, while high-efficiency models run $5,000 to $8,500 installed. Financing options, utility rebates, and manufacturer promotions can lower out-of-pocket expenses. During your free in-home estimate, we provide a written, no-surprise quote and walk you through all available incentives.