Cracked Heat Exchanger: Symptoms, How It's Confirmed and What to Ask For
Signs of a cracked furnace heat exchanger, how a technician confirms one, what to ask for if your furnace is red-tagged, and when to repair or replace it.
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For furnace repair in Newport, the visit starts with a $79 trip charge that comes off when you approve the fix, and you see the flat-rate price in writing first. We run 7am–9pm, every day of the week. Old Town's cottages and bungalows often vent into old masonry chimneys, so we test draft there.
Newport's furnace calls follow its terrain. Down in Old Town near the river, the houses are mostly cottages and bungalows, and the furnace often vents into a chimney older than anything connected to it. Blocked or crumbling flues show up there as pressure switch lockouts, rollout trips and backdrafting at the water heater.
East of Highway 61, the 1960s houses usually have furnaces that are second or third replacements, so the repairs are the familiar ones: igniters, flame sensors, inducer motors and blower capacitors. On the bluffs, larger homes push air through long ducts to far rooms, and a condensing furnace may drain to a pump because the floor drain sits across the basement. When a high-efficiency furnace stops in one of those homes, we check the condensate pump and its overflow switch early, since a full reservoir cuts the furnace off.
Updated September 26, 2026
Every furnace repair call in Newport starts with a $79 trip charge, waived when you approve the repair, and a written price before any work. Same prices in Newport as in every town we serve. National averages (HomeGuide, 2026), not our prices: a control board $300–$650, an inducer motor $400–$1,100, a PSC blower motor $500–$1,400. More in the furnace repair cost guide.

More detail on our furnace repair page.
Symptom guides: Blowing cold air · Won't ignite · Short cycling · Blinking light codes · Pressure switch trips · Strange noises · Leaking water · Burning smell · Red tag · Carbon monoxide
Often, provided it passes a safety check. We measure carbon monoxide at the furnace and in the living space, test the flue's draft and inspect the heat exchanger. If those are sound, a repair that carries you through winter is reasonable, and the replacement can wait for a milder month. A cracked heat exchanger or exhaust spilling into the basement is another matter: that furnace gets shut down until it's repaired or replaced.
Its overflow switch is doing its job. Many condensate pumps have a float that cuts power to the furnace when the pump can't empty, so the basement doesn't flood. The usual culprits are algae or sludge in the reservoir, a worn-out pump motor, a stuck check valve, or a discharge line that's kinked or sloped the wrong way. We clean or replace the pump, correct the line, then run the furnace through a full cycle.
Signs of a cracked furnace heat exchanger, how a technician confirms one, what to ask for if your furnace is red-tagged, and when to repair or replace it.
Read the guideA straight furnace swap is usually done in one day. Venting changes, a chimney liner, gas line or duct work, and the permit inspection add time. What to expect.
Read the guideBang at startup, squeal, scrape, rattle, hum, click, whistle or a rumble after shutoff: what each furnace noise means and whether it's safe to keep running.
Read the guideFurnace repair in Newport? Call or send a request.