How Much Does Heat Exchanger Replacement Cost? [2025 Data]

Normal Range: $1,250 - $3,000

Heat exchanger replacement costs average $1,750, with most homeowners paying between $1,250 and $3,000 on average. Your price depends on system size, type, labor, and location.

How we get this data
Professional checking a furnace after moving it
Photo: Tomasz Zajda / Adobe Stock Photography
Professional checking a furnace after moving it
Photo: Tomasz Zajda / Adobe Stock Photography
Highlights

  • Heat exchanger replacement restores HVAC efficiency and safety.

  • System size, type, and labor rates are key cost drivers.

  • Permits, warranties, and accessibility can increase total cost.

  • Professional installation ranges from $50 to $150 per hour and ensures warranty protection and code compliance.

  • Upgrading may improve energy efficiency and home value.

This article was created using automation technology and thoroughly fact-checked and edited by an Angi Editor in accordance with our AI policy.

Heat exchanger replacement cost averages $1,750, with most homeowners spending between $1,250 and $3,000 on average for the job. Prices vary based on the size and type of your HVAC system, labor rates, and whether additional repairs are needed. Expect higher costs for larger or high-efficiency units. A professional replacement often involves labor rates between $50 and $150 per hour. 

This guide will help you understand what drives costs and what to expect when planning your project.

Heat Exchanger Replacement Cost Factors

Understanding what drives heat exchanger replacement cost can help you budget more effectively. Here are the main factors to consider:

Size of Heat Exchanger

The size of your heat exchanger plays a major role in replacement cost. Larger heat exchangers require more materials and time to install, leading to higher expenses. The BTU rating—an indicator of heating capacity—also affects the price. Most residential systems are classified as small, medium, or large, based on the square footage they heat.

If your home uses a compact furnace, you will likely pay less than if you have a high-capacity or multi-zone system. Larger or high-efficiency units not only cost more to purchase but also require more labor to handle and install. 

Replacement Type

The type of heat exchanger in your HVAC system also impacts the replacement cost. Depending on your system, you may have a secondary heat exchanger, often found in high-efficiency furnaces. Lower-efficiency furnaces often only have a primary heat exchanger.

Heat Exchanger TypeAverage Unit CostAverage Cost (All-In)
Main heat exchanger$350–$850$1,000–$3,000
Secondary heat exchanger$300–$800$1,000–$3,000

Labor

Labor is a significant part of the total cost. HVAC technicians charge between $50 and $150 per hour, with a minimum service fee for each visit, often costing $75 to $200. Most replacements take four to eight hours, depending on system size and accessibility. Labor costs can be higher in cities or for complex projects, such as replacing high-efficiency or custom units.

Labor charges often include removing the old heat exchanger, installing the new component, testing the system, and disposing of debris. Emergency or after-hours calls may result in surcharges of $140 to $210 on top of standard rates.

Permits

Some municipalities require permits for heat exchanger replacement, especially if the work involves gas lines or major HVAC modifications. Permit fees range from $50 to $300, depending on local regulations. Inspections may be required to ensure the new installation meets safety and building codes. Skipping permits can result in fines or problems with future home sales.

Additional Features

Upgrading to a high-efficiency or specialty heat exchanger will increase your upfront cost but may offer long-term savings on energy bills. Other optional features, like corrosion-resistant materials or integration with smart thermostats, also add to the total. Extended warranties or service plans, while not required, can provide peace of mind for an additional fee.

Accessibility

Hard-to-reach installations, such as those in tight crawl spaces or on rooftops, may require additional labor and equipment rental fees. Expect higher charges if the technician must work in cramped or difficult-to-reach areas, as this increases both the time and complexity of the project.

Location

Where you live can significantly affect your heat exchanger replacement cost. Labor rates and material prices are often higher in urban areas compared to rural communities. Regions with extreme climates may require more robust, higher-capacity systems, driving up costs and replacement frequency. For example, homeowners in the Northeast or Midwest may pay more due to colder winters and higher demand for heating services.

Cleanup

The removal of old heat exchanger components costs an average of $145, and disposal costs an average of $90.

Inspections

Design and inspection fees apply if you are upgrading to a custom or advanced system. Consultation with a designer or a third-party furnace inspection may be needed for specialized installations, costing $100 to $500.

Additional Costs to Consider

Beyond the main replacement cost, several ongoing and one-time expenses can affect your overall budget.

Warranties

Warranty coverage plays a big role in your out-of-pocket heat exchanger replacement cost. Manufacturer warranties may cover parts but not labor, while extended plans could cover both. Always check if your warranty is transferable or has limitations, as this can impact resale or future repairs. If the warranty has expired, you’ll be responsible for the entire replacement cost.

Operating Costs

A new heat exchanger may lower your monthly energy bills if you upgrade to a more efficient model. The type of fuel—gas, electric, or oil—affects both operating costs and potential savings. High-efficiency systems use less energy, which can reduce your utility expenses over time.

Maintenance

Proper annual HVAC maintenance extends the lifespan of your new heat exchanger and helps prevent future repairs. Expect to pay $140 to $500 per year for routine inspections and cleaning. Regular filter changes and prompt attention to warning signs, like strange odors or reduced heating, are essential for keeping your system running smoothly.

Taxes

Sales tax and local taxes can add to your total heat exchanger replacement cost. Rates vary by state and municipality, so check with your contractor or local government for exact figures. Taxes apply to both equipment and labor in some areas, so factor this into your budget.

Insurance

Homeowners' insurance may cover heat exchanger replacement if the damage results from a covered event, such as fire or severe weather. However, normal wear and tear, neglect, or age-related failure are usually excluded. Consult your policy and file a claim promptly if you believe your situation qualifies.

DIY Heat Exchanger Replacement vs. Hiring a Pro

Some homeowners consider replacing a heat exchanger themselves to save on labor costs. DIY replacement involves purchasing the part—$300 to $850—plus tools and safety equipment. However, this project requires advanced HVAC skills, electrical knowledge, and safety certifications, and is not recommended as a DIY project.

Improper installation risks include voiding warranties, creating safety hazards (such as carbon monoxide leaks), and failing local code requirements. When dealing with heat exchangers, it’s best to hire a licensed HVAC professional to ensure safe, code-compliant installation and preserve your warranty.

Heat Exchanger Replacement vs. Repair

For safety reasons, heat exchangers that become cracked or rusted are not repairable and must be replaced. If your unit is over 10 to 15 years old or if repair costs approach or exceed 50% of replacement, replacement is the better investment. Warranty status also influences your decision, as covered repairs or replacements can lower your expenses. 

Does Heat Exchanger Replacement Add Value to Your Home?

Replacing a faulty heat exchanger can boost your home’s value, especially if you upgrade to a high-efficiency system. Improved energy efficiency, lower utility bills, and enhanced safety are attractive features for potential buyers.

A new heat exchanger also ensures your home meets local safety codes and reduces the risk of future breakdowns. While ROI varies by market and system age, investing in a reliable HVAC system is a smart move for both comfort and resale value.

Tips to Reduce Cost While Replacing a Heat Exchanger

  • Get multiple quotes from licensed HVAC pros. Comparing estimates from several local HVAC professionals helps you find the best value and ensures you’re not overpaying for labor or materials.

  • Schedule replacement during off-peak seasons. Booking your replacement in spring or fall, when demand for HVAC services is lower, can reduce labor costs and speed up scheduling.

  • Consider your needs. Balance your upfront spending with long-term efficiency. Standard models cost less initially, while high-efficiency units can save on energy bills over time.

  • Check for manufacturer rebates or local incentives. Manufacturers, local utilities, and some governments offer rebates for installing energy-efficient HVAC equipment. Check online or ask your contractor for available programs.

  • Maintain your HVAC system to prevent premature failure. Routine maintenance, like annual inspections and filter changes, extends your system’s lifespan and helps you avoid costly emergency replacements.

How Angi Gets Its Cost Data

Home is the most important place on earth, which is why Angi has helped more than 150 million homeowners transform their houses into homes they adore. To help homeowners with their next project, Angi provides readers with the most accurate cost data and upholds strict editorial standards. We extensively research project costs to develop the pricing data you see, so you can make the best decisions for you and your home. We rely on reputable sources, including the U.S. Bureau of Labor Statistics, academic journals, market studies, and interviews with industry experts—all to ensure our prices reflect real-world projects. 

Want to help us improve our cost data? Send us a recent project quote to [email protected]. Quotes and personal information will not be shared publicly.

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