Furnace Coil Pan: Repair Or Replace?

Replacing a cracked furnace coil pan can be a costly and time-consuming process, with prices ranging from $400 to $2,500. The price varies depending on the style and brand of the coil, the size and type of the furnace, and local labor rates. The two main costs are the coil, ranging from $400 to $1,900, and the labor to replace it, which can cost between $150 and $600.

The process of replacing a cracked furnace coil pan is complex and requires expertise in HVAC systems. It is not recommended for novices to attempt this repair themselves, as it could result in costly mistakes.

Replacing the coil pan yourself vs hiring a professional

Replacing a cracked furnace coil pan yourself is not recommended due to the potential risks involved and the specialised tools and knowledge required. However, if you choose to undertake this task, you should first shut off the power supply to your AC unit and remove the front panel. Observe the type of drain pan in your unit, and if it is held in place with clips or screws, remove them. There may also be a drain line connected to the pan, which you can loosen with a wrench or pliers. After detaching the pan, slide in the new one, secure it with the clips or screws, and replace the outer panel.

On the other hand, hiring a professional to replace your furnace coil pan can offer several benefits. Professionals have the necessary tools, training, and experience to handle the job safely and effectively. They can also help you choose the correct part for your specific system, as the required part depends on the system's manufacturer, model, and orientation. Additionally, they can inspect your system for any other issues, such as a damaged heat exchanger, and perform seasonal maintenance to ensure your furnace is running optimally. While hiring a professional may be more costly, it can provide peace of mind and help prevent further complications.

Whether you decide to replace the furnace coil pan yourself or hire a professional, it is important to address the issue promptly to prevent water damage and ensure the efficient operation of your system.

Regarding the cost of hiring a professional, the price can vary depending on the specific scenario and the location of the unit. For example, if the unit is in an attic and the technician needs to pump the system down and perform a proper startup, the cost could be around $1200 or more. In another case, a repair that involved recovering refrigerant, removing the coil, brazing lines, pressure testing, vacuuming, and recharging took 8 hours and cost just under $1000.

Cost of replacement parts

The cost of replacement parts for a cracked furnace coil pan can vary depending on several factors, including the size, type, brand, and location of the unit. Here is an overview of the estimated costs for the relevant parts:

Evaporator Coil

The evaporator coil is an essential component of your HVAC system, and its replacement cost can range from $400 to $1,900, with an average cost of $1,350. The labor cost for replacing the evaporator coil is typically between $400 and $1,000, as it requires a licensed technician to handle refrigerant. The total cost for replacing the evaporator coil, including labor, can range from $600 to $2,000.

Drain Pan

The cost of replacing the drain pan, or drip pan, depends on whether it is the primary or secondary pan and the material it is made of. Metal drip pans tend to be more expensive, with quotes ranging from $1,100 to $1,200. In contrast, plastic drip pans are generally cheaper, with costs ranging from $50 to $150. However, the labor cost for replacing the drain pan can vary depending on the accessibility of the unit and the complexity of the repair. In some cases, it may be necessary to recover refrigerant, cut tubing, and perform other tasks, increasing the overall cost of the repair.

Refrigerant

If your system requires additional refrigerant, you can expect to pay between $100 and $300 for this component.

Blower Motor

The blower motor circulates air through the system, and its replacement cost is approximately $475 on average.

Control Circuit Board

The control circuit board manages and coordinates various components of the air conditioner, such as the thermostat, compressor, and fan. Replacing this part typically costs around $275.

Relay Switch

The relay switch controls the electrical flow to the compressor and other vital components. Installing a new relay switch will cost about $225.

It is important to note that these estimates may not include labor costs, and the final price can vary depending on the specific circumstances of your repair or replacement. It is always recommended to consult with a professional HVAC technician to get an accurate quote for your particular situation.

Cost of labour

The cost of labour for replacing a cracked furnace coil pan can vary depending on several factors, including the complexity of the job, the experience of the technician, and the local cost of labour. Here is a breakdown of the estimated labour costs:

Hourly Rate for HVAC Technicians:

HVAC contractors typically charge by the hour for repair and replacement work. The standard hourly rate for HVAC technicians ranges from $50 to $150 per hour. However, rates can go higher during peak seasons, such as summer, when HVAC technicians are in high demand.

Estimated Labour Time for Coil Pan Replacement:

The time required to replace a coil pan can vary depending on the accessibility of the unit and the experience of the technician. A typical replacement job can take anywhere from 2 to 4 hours for a standard replacement. However, if the unit is located in a difficult-to-access area, such as an attic or crawl space, the job may take significantly longer, up to 8 hours in some cases.

Total Labour Cost Estimate:

Based on the hourly rates and estimated labour time, the total labour cost for replacing a cracked furnace coil pan can range from $100 to $800 or more. This accounts for a significant portion of the overall replacement cost, which typically includes the cost of the coil and any additional repairs.

Additional Labour Considerations:

It's important to note that labour costs can be affected by factors such as the size and configuration of the unit, the type of refrigerant required, and the need for any additional repairs or modifications. If other components of the HVAC system require attention, such as the compressor or condenser coil, the labour costs will increase accordingly.

Seeking Multiple Quotes:

To ensure you're getting a fair deal, it's recommended to get quotes from multiple HVAC companies in your area before committing to a contractor. This will help you understand the average labour rates and identify any potential additional costs associated with the replacement job.

In summary, the cost of labour for replacing a cracked furnace coil pan can vary depending on the specifics of the job and the local market rates. It's always a good idea to consult with a licensed HVAC technician to get an accurate estimate for your particular situation.

Repairing a cracked coil pan

Step 1: Inspect the Coil Pan

Before beginning any repair work, it is important to inspect the coil pan to identify the location and extent of the cracks. Remove the access panel and locate the drip pan, which is usually found under the evaporator coils or the air handler. Use a flashlight to get a clear view of the pan and pour a gallon of water into it to observe the flow. Small cracks will cause the water to drip slowly, while larger cracks will result in a steady stream. If there are no cracks, the water will drain through the PVC drain line.

Step 2: Gather the Necessary Materials

To repair the coil pan, you will need the following items: water-resistant sealant or glue, a wet vacuum cleaner, rags, industrial gloves, and fine-grain sandpaper. It is important to use a high-quality sealant that is specifically designed for this purpose.

Step 3: Turn Off the Power

Before beginning any work on the coil pan, it is crucial to turn off the power supply to your HVAC system. Locate the circuit breaker for your unit and switch it to the "OFF" position. If you cannot find the correct circuit breaker, you can turn off the main power source.

Step 4: Remove the Access Panel and Expose the Drip Pan

There are typically two drip pans in an HVAC system: a primary pan under the evaporator coil and a secondary pan at the bottom of the machine. If the crack is in the primary pan, you will need to work with it still attached to the unit. Use a rag or a wet vacuum to remove any excess water from the pan. If the crack is in the secondary pan, remove it from its nesting place and drain the water.

Step 5: Seal the Cracks

Using the water-resistant sealant, patch up the cracks that you identified in Step 1. Sand down the area around the crack with fine-grain sandpaper to help the sealant adhere better. Apply the sealant evenly on both sides of the crack and allow it to cure for at least two hours. Once the sealant has hardened, sand down any excess sealant to create a smooth finish.

Step 6: Test the Repair

To test the effectiveness of your repair, repeat the inspection process from Step 1. Pour a gallon of water into the drip pan and observe the flow. If the sealant holds, the repair was successful. Alternatively, you can switch on the power supply to the HVAC system and allow it to run for a few hours to see if the pan is still leaking.

Step 7: Reattach the Access Panel and Turn On the Power

If the repair was successful and there are no more leaks, close the access panel and turn on the power supply to your HVAC system.

While repairing a cracked coil pan is possible, it is important to note that replacing the pan is often a more durable and long-lasting solution. If you are unsure about the repair process or do not feel comfortable performing it yourself, it is best to consult a professional HVAC technician. They will have the knowledge and tools to properly diagnose and address the issue.

Signs that you need to replace your coil pan

The most obvious sign that your coil pan needs replacing is the presence of a puddle of water on the floor beneath your furnace. This indicates that the pan is cracked or damaged and is unable to contain the condensate produced by your HVAC system.

Another sign that your coil pan may need replacement is if you notice a burning smell or taste coming from your HVAC system. This could indicate that the pan is cracked and the hot furnace is causing the plastic to burn, releasing an unpleasant odour.

If your HVAC system is not cooling effectively, it could be due to a cracked coil pan. A crack in the pan can affect the airflow and the ability of the system to catch condensation, resulting in reduced cooling performance.

Additionally, if your HVAC system is making unusual noises, such as gurgling or bubbling sounds, it could be a sign that the coil pan is cracked and needs replacement. These sounds may indicate that the condensate is not draining properly and is affecting the overall function of the system.

It is important to regularly inspect your coil pan and watch out for these signs to ensure the proper functioning of your HVAC system and prevent further damage or issues.

Frequently asked questions