Cracked Heat Exchangers
Cracked Heat Exchangers | Heat Repair | Heating and Air Conditioning | Graysville
When a cracked heat exchanger threatens the comfort—and safety—of your Graysville home, HEP’s seasoned technicians move fast. We know a fissure in this hidden component can leak carbon monoxide, drive up energy bills, and leave you shivering on the coldest nights. That’s why our team arrives with cutting-edge diagnostic cameras and decades of HVAC expertise, ready to pinpoint damage others might miss and provide precise heat repair that keeps your family protected.
From the first inspection to the final test run, you’ll experience clear communication, upfront pricing, and a workmanship guarantee rooted in Tennessee pride. Whether your system needs a meticulous weld, a full exchanger replacement, or a temporary fix while you plan an upgrade, we tailor solutions to your budget without sacrificing safety or efficiency. Choose HEP for cracked heat exchangers in Graysville and feel the warmth—along with the peace of mind that your furnace is running exactly as it should.
FAQs
What is a heat exchanger and why does it develop cracks?
In a gas-fired furnace the heat exchanger is the sealed metal chamber and tubing assembly that keeps toxic combustion gasses separate from the air that circulates through your ductwork. Over years of heating and cooling cycles, the metal repeatedly expands and contracts. Normal metal fatigue, restricted airflow, overheating, rust, or improper burner adjustment can all stress the metal until hairline fractures form. Once cracked, the exchanger can no longer safely contain flue gasses, and the furnace must be serviced or shut down.
How can I tell if my furnace’s heat exchanger is cracked?
Signs include soot inside the furnace cabinet, unusual odors that smell like formaldehyde, visible corrosion or rust flakes, a yellow or wavering burner flame instead of steady blue, and unexplained carbon-monoxide detector alarms. You may also notice the furnace cycling on and off rapidly. Because many cracks are hidden inside the exchanger walls, the most reliable method is a professional inspection using mirrors, borescopes, and combustion analysis tools.
Is a cracked heat exchanger dangerous?
Yes. A crack allows exhaust gasses—carbon monoxide, nitrogen dioxide, sulfur dioxide—to mix with the breathing air in your home. Even low levels of carbon monoxide can cause headaches, dizziness, and nausea, while higher concentrations can be fatal. For that reason building codes and equipment manufacturers require furnaces with confirmed exchanger cracks to be shut off until repaired or replaced.
Can a cracked heat exchanger be repaired or does it need replacement?
Heat exchangers are factory-sealed safety components; welding or patching is not approved by any furnace manufacturer. If the furnace is still under the heat-exchanger warranty, we can often replace just the exchanger assembly. On older units out of warranty, full furnace replacement is usually more cost-effective, because labor for exchanger replacement can approach the price of a new high-efficiency system.
How much does it cost to replace a cracked heat exchanger in Graysville?
Costs vary by furnace brand, model, and age. For a part-only warranty swap, homeowners typically pay between $600 and $1,200 for labor and incidental materials. Out-of-warranty exchanger replacements range from $1,500 to $2,500. If you opt for a complete furnace upgrade, expect installed prices of $3,500 to $6,000 for a modern 95%-plus AFUE unit. We provide free written estimates so you can compare options before committing.
How fast can your Graysville team respond to a cracked heat exchanger call?
During heating season we prioritize no-heat and safety calls. If you contact us before noon, we can usually have a certified technician at your Graysville address the same day—often within 2–4 hours. After-hours and weekend emergency service is available 24/7 for an additional fee. Our trucks carry combustion analyzers, inspection cameras, and common furnace parts so we can diagnose the exchanger and secure the system on the first visit.