Cracked Heat Exchangers
Cracked Heat Exchangers | Heat Repair | Heating and Air Conditioning | Sevierville
When a cracked heat exchanger threatens to fill your Sevierville home with cold air—or worse, dangerous fumes—HEP’s seasoned technicians move fast. We pinpoint the fracture, share clear photos of the damage, and walk you through options that range from precision welding and part replacement to a full system upgrade. Our vans roll out stocked with factory-authorized parts, so most repairs are finished on the very first visit, restoring safe, even warmth before the mountain chill settles in for the night.
Homeowners love us for upfront pricing, courteous clean-up, and workmanship backed by a rock-solid guarantee. Because every minute without heat matters, our 24/7 dispatch eliminates guesswork and waiting rooms; you book online or by phone, and we text you when the tech is en route. From emergency heat repair to routine maintenance that prevents future cracks, HEP keeps Sevier County comfortable, efficient, and worry-free all winter long.
FAQs
What are the most common warning signs that my furnace’s heat exchanger is cracked?
Watch for a yellow or flickering burner flame, a strong metallic or formaldehyde-like odor, soot buildup inside the cabinet, water pooling at the base of the furnace, visible corrosion or hairline cracks on the exchanger walls, and frequent or unexplained tripping of your carbon-monoxide (CO) alarm. If you notice any of these symptoms in your Sevierville home, shut the system off and call us immediately for a professional inspection.
Why is a cracked heat exchanger considered so dangerous?
A damaged heat exchanger can let flue gases—especially odorless, colorless carbon monoxide—escape into your home’s air stream. Prolonged exposure can cause headaches, dizziness, nausea, flu-like symptoms, or even death. Cracks can also allow flame rollout, increasing the risk of fire inside the furnace cabinet. For these reasons, building codes and HVAC safety standards require the system to be shut down until the exchanger is repaired or the furnace is replaced.
Is it better to repair the cracked heat exchanger or replace the entire furnace?
It depends on three factors: the age of your furnace, the extent of the damage, and overall efficiency. If your unit is less than 10 years old, still under warranty, and the crack is isolated, replacing just the heat exchanger can make financial sense. If the furnace is 10–15+ years old, out of warranty, or has multiple cracks or rust damage, replacement is usually more cost-effective and brings you the added benefit of higher efficiency, lower utility bills, and a new manufacturer warranty. Our Sevierville technicians will give you honest, code-compliant options after inspection.
How quickly can your Sevierville team diagnose and fix a cracked heat exchanger?
We provide 24/7 emergency service across Sevier County. In most cases, a certified technician can be at your door the same day you call. A comprehensive diagnostic—including camera inspection of the heat exchanger—takes about 60–90 minutes. If only the exchanger needs replacing and the part is in stock, repairs usually take 3–5 hours. For full furnace replacement, expect 4–8 hours, including safe removal and haul-away of the old unit, new system installation, start-up, and final safety check.
What does it cost to repair or replace a cracked heat exchanger in Sevierville?
Costs vary by furnace brand, model, and availability of parts. Replacing just the heat exchanger generally runs between $600 and $2,000, including labor. A complete furnace replacement typically starts around $3,500 and can reach $7,500 or more for high-efficiency models. We charge a modest diagnostic fee that is credited toward any approved repair or replacement. Before work begins, you’ll receive a written, no-surprise estimate and information on financing and utility rebate options available to Sevier County residents.
How can I prevent heat exchanger cracks and extend the life of my HVAC system?
1) Schedule professional maintenance every fall so a technician can clean burners, check combustion settings, and inspect for early signs of metal fatigue. 2) Change or clean filters monthly during peak heating months—restricted airflow makes the exchanger overheat and weaken. 3) Keep supply and return vents open and unobstructed. 4) Install and regularly test CO alarms on every floor of your home. 5) Consider adding a whole-home humidifier; extremely dry air accelerates metal fatigue. 6) Make sure the furnace is the right size for your home—a unit that cycles on and off too frequently places stress on the heat exchanger. Following these steps can add years to your system’s life and keep your family safe.