Cracked Heat Exchangers
Cracked Heat Exchangers | Heat Repair | Heating and Air Conditioning | Oak Ridge
When a cracked heat exchanger starts leaking carbon monoxide or slashes your system’s efficiency, every minute without trustworthy help feels longer than an East Tennessee winter night. Homeowners across Oak Ridge count on HEP’s certified technicians to diagnose the damage fast, explain your options in plain language, and restore warmth and peace of mind without the sticker shock. We service all makes and models, so whether your unit is barely limping along or has shut down completely, you’re only one call away from responsive, local experts who treat your home like their own.
From emergency heat repair to proactive maintenance that keeps future cracks at bay, HEP brings the latest tools, genuine replacement parts, and decades of HVAC know-how right to your door. Transparent pricing, background-checked pros, and a satisfaction guarantee mean you’ll stay comfortable today—and confident tomorrow. Call or click now, and breathe easy again before the next cold front hits Oak Ridge.
FAQs
What exactly is a heat exchanger and why does it crack?
In a gas-fired furnace, the heat exchanger is a sealed metal chamber that transfers heat from the burner flames into the air circulating through your ducts while keeping combustion gases separate from the indoor air. Over time, repeated heating and cooling cycles cause the metal to expand and contract. Factors such as age (10–20 years), inadequate airflow, oversized equipment, or corrosion from moisture can weaken the metal and lead to stress fractures or holes—commonly referred to as a "cracked heat exchanger."
How can I tell if my furnace in Oak Ridge has a cracked heat exchanger?
Warning signs include a lingering smell of formaldehyde or burnt metal, visible soot inside the cabinet, unexplained tripped carbon-monoxide detectors, water collecting at the base of the furnace, and odd flames (yellow or wavering) when the burner fires. Because cracks are often hidden, our Oak Ridge technicians use specialized inspection mirrors, cameras, and combustion analyzers to confirm the problem during a diagnostic visit.
Is a cracked heat exchanger really dangerous?
Yes. A crack can allow carbon monoxide (CO), nitrogen dioxide, and other combustion by-products to mix with the household air. Even low levels of CO can cause headaches or nausea, and high concentrations can be lethal. For this reason the Tennessee Mechanical Code and most equipment manufacturers require immediate shutdown of a furnace once a cracked exchanger is verified. Safety should be the top priority.
Can you repair a cracked heat exchanger or does it have to be replaced?
Because the exchanger is sealed, welded, and tested at the factory, field repairs are not considered safe or code-compliant. The standard solution is either to replace the heat exchanger assembly (if the part is under warranty and the furnace is otherwise in good condition) or replace the entire furnace. Our Oak Ridge team will compare costs, warranty status, and energy-efficiency gains with you before you decide.
How much does it cost to replace a cracked heat exchanger in Oak Ridge?
Costs vary with furnace brand, size, and warranty coverage. If the heat exchanger is still under the manufacturer’s 10- or 20-year warranty, you may only pay labor—typically $600–$1,000. Out-of-warranty exchanger replacements generally range from $1,200–$2,000. If the furnace is 12+ years old, a full system replacement (often $3,500–$6,000 depending on efficiency) can offer better value through lower energy bills and a new warranty.
How quickly can you restore my heat if my exchanger is cracked, and do you offer emergency service?
We provide 24/7 emergency heating service throughout Oak Ridge and Anderson County. In most cases we can diagnose a cracked heat exchanger the same day you call. If the replacement part is in stock, we can have heat back on within 24 hours. For full furnace replacements, installation is usually completed in one day once equipment arrives. Temporary space heaters are available if a parts order or permit inspection creates a longer wait.