Have a 12 year old Rheem 5 ton system that just had a yearly service and there is a small coolant leak somewhere in the system. Losing a little less than a lb a year in coolant. On top of that the fan blade was loose and the fan motor and capacitor are needing to be replaced in the next year. Service also showed some growth in the plenum and they recommended replacement.

All in the replacement of the fan, fan motor, capacitor, plenum with a UV led light to kill mold growth was around $5000 without the leak repair which I imagine is a condenser coil, probably another $1500.

After getting the repair quote I had them quote a full system replacement to get an idea and that was around $15k for compressor, furnace, plenum and putting the furnace vents in which are non existent due to house being from 1979. Brand being quoted is Day and Night. Am I right to think the full system replacement is the way to go in a few months? Anything I am missing? Should I wait till the fall for another quote when it's normally cheaper to replace?

Yes, I also was a frog in a pot of ever-warming water on the stove, resisting Replace over Repair in those waning years. After all, Carrier was the original and always a good brand. 20-20 hindsight & spreadsheet proved that we eventually paid 76% in Repairs compared to this system's New price in-the-day.
Parts found were out of town & "last one" with supply/demand prices & delays
in the 14-20 life ending years that finally forced us into an all New (sans ducts) system.

Happily the learning curve with New is EZier than other Gen-Z gadgets and never been so HVAC pampered in comfort & energy bills since 1980 in this aging, leaky house.
$16k 4Ton Variable HeatPump Trane, almost top grade in-the-day, long-time expert installers (Aggieland attacts the best, in all brands).

As for brands, Consumer Reports has lots of data for their ratings but also most will advise, it's equally important WHO installs a system, as some can take a perfectly good SEER and cut it in half ... for starters.

Let us know how it all turned out?

I can't really give you any advice on the potential 'mold' issue in the plenum. I just don't have any experience there.

But, if all you need (other than the small refrigerant leak) is a new fan motor and capacitor, and perhaps a fan blade (if it doesn't just need to be tightened on the shaft), I'd say $5K is way, way high. A single-speed fan motor will cost about $150 for parts, and a capacitor about $25 for an American-made one.

Now, if you don't do it yourself, you need to pay for the labor, and those guys don't come cheap and do deserve to be paid -- just not at heart surgeon rates.

As for small refrigerant leaks -- always check for the easy stuff first. Many times I find leaks on the caps for the service ports. A new cap/gasket and a little Nylog Blue will almost always fix that, even if the Schrader valve stem is leaking. *

I also see leaks sometimes on the large metal caps that cover the service valves. Many times a little Nylog Blue will take care of those as well.

You can check for leaks yourself with a $10 liquid leak detector solution. If you want to get more 'pro', spend about $250 for an electronic leak detector, and you'll be able to find leaks just about anywhere, including in the condenser or evaporator coils.

Leaks in the condenser (outdoor) coils are fairly rare, barring mechanical damage. Leaks in the evaporator (indoor) coils are more common. It seems I get about 10-15 years on an evaporator coil. I've never had a condenser coil leak, but hey, anything is possible.

Good luck. If you just want to buy a new system, get one. It's your money and home.

* {If you want to actually change out leaking Schrader valve stems while the system is still charged, you need to buy a valve stem tool for about $75 to do it. It's not hard}.

The $5k includes the new plenum ($2500) and a $600 UV light to prevent mold. It still seems high but not sure if that is summer pricing?

Bert315 said:

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The $5k includes the new plenum ($2500) and a $600 UV light to prevent mold. It still seems high but not sure if that is summer pricing?

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HVAC trades certainly are busier when it's hot, and guys can be pickier about which jobs they'll take and how much they'll charge.

I've known some HVAC guys who've left that work for the electrical trades (generally industrial stuff) because they told me they'd feast in the summer and starve in the winter.

So, to your question -- if you can put it off 'till November, I'll bet you can get some more 'reasonable' quotes, especially if you check with 3 or 4 different companies.

kubiak03 said:

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He wants to sell you a new system

Get a second opinion

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And a couple of estimates on a new system.

The UV system is somewhat snake oil. While yes, UV will kill things, it also degrades the components in the system not metal. You'll degrade the system from the inside out.

UV lights also have a steady degradation factor. A bulb with 2000 hours will not put out the same amount of UV rays as a new bulb; the UV rays are what 'kill' the bugs. So the intensity goes down and you'll have to change it out after a year or two. If there is not enough UV intensity, you just have a flashlight in your HVAC system.

Also, the UV (assuming it is in the downstream side of the evaporator (cold box upstairs) will only penetrate so far into the tube bundle. Maybe the 3rd row (depends on tube layout). You won't be killing everything, just where light can hit. And if you put in the upstream side, you'll kill stuff going into the box, but then the box will 'refill' the air with mold (if it is actually present) and blow it out.

The other parts are 'typical' repair parts, so I could see a little increase in price because it's summer.


The question that needs to be asked is what is the age of the other 'stuff'? For example, my house is mid 1980's. I've installed the 3rd (maybe 4th) unit, but prior to this changeout, all of the ducts, supports, insulation, etc. were all original. My return ducts were undersized; the actual ducts were leaking; the plenum boxes had 3-6 layers of tape (and all leaking). So your system is struggling, but you haven't set it up for success. Part of the advantage of replacing the system is 'fixing' all the other stuff and getting it all new again.

Think about the system as a car. You've changed the oil, added gas, but never fixed the tires (unless they pop), haven't really cleaned it out or washed it. Been driving it every day for 15 years. Going to be as good a new car? Would changing out the engine (or other parts) fix it? Interior still going to be good?

~egon

With a 12-year-old system and multiple issues piling up, I'd lean toward replacement, especially if you plan to stay in the house long-term. That coolant leak plus aging components means you'll keep sinking money into repairs. Waiting until fall could save you a bit, quotes are usually lower then. It might be worth getting a second opinion or quote from another company. I had a great experience with the guys from hvac service in sacramento https://alphamechanicals.com/ Local providers can sometimes offer more competitive pricing or catch things others miss, especially with older homes like yours.

Had a second opinion from another AC company my neighbor uses. Said he didn't see any oil or signs of a leak in the coils but did see where a fitting was loosened and insulation pulled back. Also checked and said the fan motor was operating at normal amps and wasn't a problem.

He acknowledged the plenum but said it was what he would expect for a system like mine. I'm really frustrated and waiting till this week to talk with my old AC company. It sounds like their technician might have loosened a fitting which allowed the leak. Does this sound reasonable?

I think I'd switch my business to the second guy and forget about fooling with the first again.

You'd like to think that no tech would ever intentionally cause a leak, and perhaps that's not what happened with the first guy. But still ...

Ribeye-Rare said:

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I think I'd switch my business to the second guy and forget about fooling with the first again.

You'd like to think that no tech would ever intentionally cause a leak, and perhaps that's not what happened with the first guy. But still ...

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Agreed, would like to think that's not the case. Took the 2nd guy no time to spot where the leak was. He said he wasn't going to accuse anyone but said he hadn't seen anything like that before without someone loosening it intentionally.

My main point in talking to the old company is I've been paying them a monthly rate that gives me the 2 check ups each year and a discount on any work that goes on. It basically nets out equal without any repairs but I have to let them know I'm cancelling and want to give them why. Disappointed as I've know the family from church for 20+ years. The tech isn't part of the family but still disappointed

1. Church referrals = The Worse and often die/retire b4 warranty ends
(You hit my button with a few kudo exceptions)

2. Status as a a biannual Paid Member service = elite BUT then the front office maroons are segregated from the biz relationship & client particulars = sends the new guy out = Not My Job (Duh) & no Biz concerne that will prosper ME

A simple phone call=
Best guy sent out to fix em OR
Another idiot arrives = we shop & graduate to a better service

Huh?