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Heat exchanger split after 4 years, misadjusted burner the cause?
We've just been notified by our furnace repair company (who is also our oil dealer) that our heat exchanger in our 17 year old Heil forced warm air furnace needs replacement. We replaced the heat exchanger, at our cost, 4 years ago since there was only a 10 year warranty on the original at the time.
The furnace has been fine all season long. No fumes in the house, nothing. Somehow, however, that changed when they came to do the annual furnace cleaning. After the service person left the furnace stopped working some hours later. 3 service calls later, waking up at 3 a.m. to a house full of oily smelly fumes, a number of additional cleanings and adjustments of the nozzles, we find out that the heat exchanger has split along the seam where it is bolted together.
Is it possible that a poorly adjusted furnace can overheat or otherwise cause the exchanger to split? We are perplexed that our heat exchanger should break after only 4 years, and suspicious that a poor servicing has damaged our property.
Thanks in advance,