When does HVAC repair make more sense than replacement?

Short answer

In many cases, HVAC repair makes more sense than replacement. Unless there is a verified safety failure, such as a proven cracked heat exchanger, or a system that is very old or uses obsolete parts, most systems can be repaired safely and effectively.

Replacement is sometimes the right choice, but it is far from the only option in many situations.

How often systems can actually be repaired

In our experience, most HVAC systems can be repaired unless one of a few specific conditions exists.

For furnaces, replacement may be necessary if there is a confirmed heat exchanger failure, the system is more than 20 years old, or it uses obsolete parts that are no longer available.

For air conditioners and heat pumps, replacement should be considered when the compressor has failed, the system uses obsolete parts, and the equipment is more than 20 years old. In those situations, the cost and practicality of repair often no longer make sense.

Outside of these scenarios, many systems that are recommended for replacement could continue operating safely and reliably with proper repairs.The factors that actually matter when deciding

There are several important factors to consider when deciding between repair and replacement.

These include the cost of the repair, the age of the unit, safety concerns, system reliability, and the likelihood of continued repairs in the near future. All of these factors should be evaluated together, not in isolation.

What tends to be overplayed in replacement discussions are safety concerns and repair costs, especially when those concerns are not clearly explained or supported with evidence.

A common fear-based recommendation homeowners hear

One of the most common fear-based reasons homeowners are told they need to replace a furnace is a cracked heat exchanger.

A cracked heat exchanger is a serious issue and should be taken seriously when it is real. However, it is also one of the most commonly misused replacement justifications.

In Spokane County, technicians working on gas furnaces must hold a gas mechanic’s license. That license means we are required to take action if we find a truly dangerous condition. If a technician tells you your heat exchanger is cracked but leaves your furnace running and heating your home, that is a major red flag.

A furnace with a confirmed cracked heat exchanger should not continue operating, because it can be dangerous. That is why this claim is so powerful, and why it should always be verified.

When replacement genuinely makes sense

There are times when replacing an HVAC system is the right decision.

Replacement should be seriously considered when a furnace or air conditioner is over 20 years old and the cost of repairs exceeds $1,000. At that point, it becomes reasonable to weigh long-term reliability and value.

Replacement also makes sense when a heat exchanger is truly cracked in an older furnace. For air conditioners and heat pumps, replacement is often the better option when there is a failed compressor or a refrigerant leak in a system that uses R22.

When repair almost always makes sense

Repairs often make sense when the system is under 20 years old and the issue is a single component failure.

Items like blower motors, capacitors, and other electrical components wear out over time. Replacing these parts can restore proper operation without the cost or disruption of full system replacement.

In many cases, these repairs can extend the life of a system significantly.

Questions homeowners should always ask before replacing

Before agreeing to replace an HVAC system, homeowners should ask to see clear proof of the problem.

If you are told your heat exchanger is cracked, ask to see a live image of the crack using a camera, not just a photo on a phone. You should also ask for a repair quote. If a company is unwilling to provide a repair option, that should raise concern.

Getting a second opinion is also a smart step, even if it is not from us. One important tip is not to tell the second company what the first company recommended. This helps ensure an unbiased evaluation.

How Bigfoot approaches repair versus replacement

Bigfoot is a repair-first company. We will always provide a repair option when it is safe and reasonable to do so.

If replacement is also worth considering, we will explain why and provide both options. Our role is to give you clear information so you can make the decision that makes sense for your home, without pressure.

Safety & Educational Disclaimer

The information provided in this article is intended for general educational purposes only. HVAC systems involve electrical, gas, and mechanical components that can pose serious safety risks if handled improperly.

Homeowners should never attempt repairs, bypass safety devices, or perform work beyond basic visual checks and filter replacement. Any troubleshooting described is meant to help homeowners recognize potential issues, not to diagnose or fix them.

If you are unsure about a situation, notice unusual smells, sounds, error codes, or safety concerns, stop and contact a qualified HVAC professional. Bigfoot Heating & Cooling is not responsible for injury, property damage, or system damage resulting from attempts to perform HVAC work without proper training and equipment.


Still Have Questions?

If you’ve been told your system needs to be replaced and you’re unsure whether repair is still an option, we’re happy to help.

You can learn more about our HVAC Repair, Installations and Replacements, or Second Opinions services, or reach out to talk through your situation before making a decision.

Four men standing in front of a dark curtain, smiling for a photo. They are wearing black and tan T-shirts with a logo that reads 'B&C Mechanical' and their names printed on the shirts.