Cracked Heat Exchangers
Cracked Heat Exchangers | Heat Repair | Heating and Air Conditioning | New Market
When a cracked heat exchanger starts leaking carbon monoxide or slashes your system’s efficiency, you can’t afford to wait. HEP’s certified technicians arrive fast in New Market with digital diagnostic tools, genuine replacement parts, and the know-how to restore safe, consistent warmth. We’ll walk you through the damage, show thermal images of the cracks, and quote transparent pricing before lifting a single wrench—so there are no surprises, just solutions.
From emergency heat repair at 2 a.m. to preventive maintenance that keeps cracks from forming in the first place, we treat your home like our own. Every visit is backed by industry-leading warranties and the friendly, “Happy HEP” service that’s made us East Tennessee’s comfort partner for decades. Don’t let a fractured exchanger chill your winter or threaten your family’s air quality; call the local team that makes broken heaters whole again.
FAQs
What causes a heat exchanger to crack in the first place?
Over time, repeated heating and cooling cycles make the metal in a furnace’s heat exchanger expand and contract. If the system is undersized, poorly maintained, or has restricted airflow (dirty filters, closed vents, failed blower motor), the exchanger can overheat and weaken. Corrosion from combustion by-products, excessive vibration, or incorrect gas pressure can also create stress points that eventually split. Our New Market technicians inspect these contributing factors so we can correct the root cause—not just the symptom.
What symptoms should I watch for that indicate a cracked heat exchanger?
Common red flags include: a strong or unusual odor (like formaldehyde) when the furnace runs, visible soot or corrosion around burners, higher than normal carbon-monoxide readings detected by CO alarms, burner flames that flicker or roll out when the blower starts, unexplained headaches or flu-like symptoms in occupants, and an audible popping or banging as metal expands. If you notice any of these signs in your New Market home, turn the furnace off and call us immediately for a safety inspection.
Is it dangerous to keep running my furnace if the heat exchanger is cracked?
Yes. A cracked exchanger can allow combustion gases—including carbon monoxide—to mix with the air that circulates through your ducts. This colorless, odorless gas can cause nausea, dizziness, and even be fatal in high concentrations. Even small leaks reduce efficiency and can damage other furnace components. For safety, we advise shutting the system down and scheduling a same-day evaluation; our team is on call 24/7 in New Market for situations like this.
How do your technicians verify that the heat exchanger is actually cracked?
We use a multi-step diagnostic process: visual inspection with high-intensity lights and mirrors; combustion analysis for abnormal CO or oxygen levels; camera scopes that let us see deep inside tubular or clam-shell exchangers; and pressure tests to detect leakage paths. We document all findings with photos or video and review them with you so you can make an informed decision about repair or replacement.
Can you repair a cracked heat exchanger, or does the furnace have to be replaced?
For most residential gas furnaces, manufacturers prohibit welding or patching heat exchangers because any change can compromise structural integrity and void safety certifications. In nearly every case, the exchanger or the entire furnace must be replaced. If your furnace is under warranty, we can often source just the exchanger; otherwise, a full system replacement may be more cost-effective. We provide both options, complete cost breakdowns, and financing to fit your budget.
How quickly can you replace a cracked heat exchanger in New Market, and what will it cost?
We maintain stocked service vehicles and have local warehouse access, so in many cases we can replace an exchanger—or install a new furnace—the next business day after diagnosis. Emergency portable heaters are available while you wait. Pricing varies by furnace make, model, and warranty status, but exchanger replacements typically range from $900–$2,000, while full furnace replacements start around $3,500. Before any work begins, you’ll receive a written, no-surprise estimate and details on rebates, utility incentives, and financing plans available to New Market residents.