Cracked Heat Exchanger: Symptoms and How It's Confirmed
Signs of a cracked furnace heat exchanger, how a technician confirms it with a camera and CO readings, what to do after a red tag, and repair vs replace.
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Monticello furnace repair is a $79 trip charge, waived when you okay the repair, with the written flat-rate price in hand before we start. Many furnaces from the town's 1990s–2000s growth vent PVC through a side wall that can ice over.
Most of Monticello's furnaces date from its fast-growth years, and the ones still running are well into their second decade or beyond. The newer ones are 90%-plus models venting PVC out a side wall, and their winter calls are specific: a condensate line that freezes where it runs along an outside wall or into a cold garage, a trap that plugs, an exhaust termination that ices over or disappears under a drift. Each of those shuts the furnace down at the pressure switch, often at the coldest hour of the night.
Older houses near downtown with chimney-vented furnaces, where draft problems and worn inducers are more common. Basements finished after move-in sometimes wall the furnace into a small room without enough combustion air. We check venting and drainage along with the failed part, since the cause is often outside the cabinet.
Updated October 27, 2026
National averages (HomeGuide, 2026), not our prices: a limit switch $100–$375, a PSC blower motor $500–$1,400, a variable-speed (ECM) blower motor $800–$2,300. More in the furnace repair cost guide.
Symptom guides: Carbon monoxide · Blowing cold air · Won't ignite · Short cycling · Signs your furnace needs a technician
Very likely. A high-efficiency furnace makes water all winter, and a drain line or condensate pump in an unheated garage or along a cold wall can freeze solid. When the water can't leave, it backs up into the trap, the pressure switch opens and the furnace shuts down. Thawing it gets you through the night. The lasting fix is rerouting the line to a warm space or adding heat tape, which we can price on the visit.
On furnaces 20 to 30 years old, we see inducer motors, control boards and blower motors wear out, along with cracked heat exchangers on some models. A single failed part can still be worth fixing, and we'll write the price. Per HomeGuide, typical national ranges are $400–$1,100 for an inducer motor and $300–$650 for a control board. Past 20 years, weigh that against a new furnace before approving a big repair.
Signs of a cracked furnace heat exchanger, how a technician confirms it with a camera and CO readings, what to do after a red tag, and repair vs replace.
Read the guideA red tag means a technician or the gas utility found your furnace unsafe and shut it off. Common reasons, what not to do, and how to get a second opinion.
Read the guideFurnace out on a cold Minnesota night? The checks to make in order, reading the blink code, keeping pipes safe while you wait, and when to call 612-429-3465.
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