Is Your Heat Exchanger Cracked? Warning Signs That Could Save Your Life

Last winter, I got a call at 2 AM from a family in Uptown who woke up feeling dizzy and nauseous. Their carbon monoxide detector was screaming, and they had no idea why. When I arrived, I found a cracked heat exchanger that was slowly poisoning their family while they slept. That’s a call I never want to get again, but sadly, it happens more often than you’d think in Minneapolis.

A cracked heat exchanger isn’t just a furnace problem—it’s a life-threatening emergency that can fill your home with deadly carbon monoxide gas. After 17 years of responding to CO emergencies across Minneapolis, I’ve seen firsthand how quickly this silent killer can affect families. The scary part? Most people don’t realize they’re in danger until symptoms start appearing.

Why Families Trust Me With Their Safety

When your family’s life is on the line, you need someone who’ll be there fast and get it right the first time. I started MplsCOEmergency in 2008 because I saw too many families putting their trust in companies that didn’t understand the urgency of CO emergencies. Here’s what makes us different:

• 30-minute emergency response guarantee – When you call, I’m already heading to my truck
• True 24/7 availability – No answering service, just me picking up the phone
• 17+ years specializing in CO emergencies – I’ve handled over 3,000 CO-related calls in Minneapolis
• Owner-operated business – You get my personal cell number and direct access to me
• No upselling games – I only fix what’s actually broken and dangerous

“I’ve been doing this for 17 years, and I can tell you that cracked heat exchangers are the most dangerous furnace problem you can have. They’re silent, they’re deadly, and they don’t give you a second chance to fix them,” says Mike, owner of MplsCOEmergency.

I Know Minneapolis Furnaces Like the Back of My Hand

Minneapolis homes present unique challenges that I’ve been dealing with for nearly two decades. Our brutal winters push furnaces to their limits, and many of our beautiful older homes have aging HVAC systems that need special attention.

I’ve worked in every neighborhood from the historic homes in Loring Park to the newer developments in Northeast Minneapolis. I know which brands of furnaces are common in each area, what problems to expect based on the age of your home, and how Minneapolis’ harsh climate affects heat exchanger longevity.

Last month alone, I found cracked heat exchangers in three different Century-old homes in the Whittier neighborhood. These older homes often have furnaces that have been running for 20+ years, and the constant heating and cooling cycles eventually take their toll on the metal components.

Here’s Exactly How I Handle Your CO Emergency

When you call me about a suspected cracked heat exchanger, here’s what happens step by step:

1. Immediate Safety Assessment (5 minutes) – I test CO levels throughout your home and make sure your family is safe
2. Furnace Shutdown if Necessary – If I detect dangerous CO levels, I shut down your furnace immediately
3. Heat Exchanger Inspection (15-20 minutes) – I use specialized cameras and mirrors to examine every inch of your heat exchanger
4. Documentation and Explanation – I show you exactly what I found and explain it in plain English
5. Repair or Replacement Options – I give you honest recommendations based on safety and your budget
6. Safety Testing Before Leaving – I never leave until I’m confident your home is safe

All the Ways I Can Help Keep Your Family Safe

Here are the specific services I provide to protect Minneapolis families from carbon monoxide poisoning:

• CO Leak Detection – Using professional-grade equipment to find even trace amounts of carbon monoxide in your home
• Emergency CO Response – 24/7 immediate response when your CO detector goes off or you suspect a leak
• Furnace Repair – Fixing the root cause of CO production, not just patching symptoms
• Heat Exchanger Inspections – Detailed visual and camera inspections to catch cracks before they become dangerous
• Carbon Monoxide Safety Inspections – Annual safety checks to prevent CO problems before they start
• CO Detector Installation – Proper placement and installation of CO detectors throughout your home
• Furnace Maintenance Plans – Preventive maintenance to catch heat exchanger problems early
• Insurance Claim Assistance – Help documenting CO damage for your insurance company
• Landlord Safety Checks – Required CO safety inspections for rental properties
• Real Estate CO Audits – Pre-sale or pre-purchase CO safety inspections

Need emergency CO response right now? Click here for immediate help.

What Sets Me Apart From Other HVAC Companies

Most HVAC companies treat cracked heat exchangers like any other repair job. I treat them like the life-threatening emergencies they are. Here’s what my customers tell me makes the difference:

• Specialized CO Training – All my techs have advanced carbon monoxide emergency training
• Professional Equipment – I use hospital-grade CO detection equipment, not basic detectors
• Insurance and Bonding – Fully licensed (Minneapolis HVAC Class A), bonded, and insured
• Plain English Communication – I explain everything in terms you can understand
• Community Focus – I live in Minneapolis too, and I care about keeping our neighbors safe

“The biggest mistake I see homeowners make is ignoring the early warning signs of a cracked heat exchanger. By the time your CO detector goes off, you’ve already been exposed to dangerous levels of carbon monoxide,” explains Mike.

Recent Emergency Calls I’ve Handled Around Minneapolis

Here are some real situations I’ve dealt with recently (names changed for privacy):

• Uptown – Responded to a family of four experiencing headaches and nausea; found a 6-inch crack in their 15-year-old furnace’s heat exchanger
• Northeast Minneapolis – Emergency call at 3 AM for CO detector alarm; discovered corroded heat exchanger in basement furnace
• Whittier – Annual inspection revealed hairline cracks in heat exchanger of 1920s home with original ductwork
• Loring Park – Real estate inspection found dangerous CO levels traced to cracked heat exchanger in luxury home
• South Minneapolis – Landlord safety check revealed multiple furnace issues including cracked heat exchanger in duplex

“Mike saved our lives. We had been feeling sick for weeks and thought it was just winter flu. When he tested our home, the CO levels were off the charts. I can’t thank him enough for his quick response and honest service.” – Zelda K., Uptown, January 2025

Every Minneapolis Neighborhood I Serve

I provide emergency CO response and heat exchanger inspections throughout the Minneapolis metro area. No matter where you live, I can be there fast when you need me.

See the complete list of areas I serve and response times for each neighborhood.

Questions I Get About Cracked Heat Exchangers

How long does it take for a cracked heat exchanger to become dangerous?

It depends on the size of the crack and how much you’re using your furnace. A small crack can become life-threatening within days during our Minneapolis winters when furnaces run constantly. That’s why I always recommend immediate inspection if you suspect any problems.

Can I still use my furnace if the heat exchanger is cracked?

Absolutely not. A cracked heat exchanger can leak carbon monoxide into your home every time your furnace runs. Turn off your furnace immediately and call me for emergency service. Your family’s safety is worth more than a cold house.

Will my insurance cover heat exchanger replacement?

Many insurance policies cover sudden and accidental damage to heat exchangers, especially if there’s CO damage to your home. I help document everything you need for your insurance claim, and I’ve worked with most major insurance companies in Minneapolis.

How much does it cost to fix a cracked heat exchanger?

The cost depends on whether you need repair or replacement. Minor cracks might be repairable for $500-800, but most cracked heat exchangers need replacement ($1,200-2,500). I always give you honest pricing upfront with no surprises.

What causes heat exchangers to crack in Minneapolis homes?

Our extreme temperature swings are the biggest culprit. When your furnace heats up and cools down repeatedly during our harsh winters, the metal expands and contracts, eventually leading to stress cracks. Poor maintenance and dirty filters make the problem worse. Learn more about furnace age and CO risks.

Insider Tips to Protect Your Family

After 17 years of CO emergencies, here’s what I wish every Minneapolis homeowner knew:

• Check your furnace flame monthly – It should be blue, not yellow or orange. A yellow flame means incomplete combustion and possible CO production
• Install CO detectors on every level – Put them about 5 feet off the ground, not on the ceiling like smoke detectors. Follow my detailed placement guide
• Never ignore flu-like symptoms in winter – If multiple family members feel sick only when at home, test for CO immediately
• Keep your furnace filter clean – A dirty filter forces your furnace to work harder, accelerating heat exchanger wear
• Schedule annual inspections – Catching heat exchanger problems early can save your life and your wallet
• Know the age of your furnace – Heat exchangers typically start developing problems after 15-20 years in Minneapolis

“I always tell my customers that carbon monoxide doesn’t give you a second chance. The time to fix a cracked heat exchanger is before it starts leaking CO into your home, not after your family starts getting sick,” emphasizes Mike.

The Reality of Living With CO Risks

Let me be straight with you about carbon monoxide dangers. The benefits of catching heat exchanger problems early are obvious – you protect your family’s health and avoid emergency repairs. But there are challenges too.

Professional CO testing and heat exchanger inspection costs money upfront, and sometimes I find problems that require expensive repairs. Some families put off the inspection because they’re worried about what I might find. But here’s the thing – ignoring a potential CO problem doesn’t make it go away, it just makes it more dangerous.

I’ve seen families spend thousands on emergency room visits for CO poisoning that could have been prevented with a $200 inspection. I’ve also seen insurance companies deny claims because homeowners didn’t have regular maintenance records.

The honest truth is that maintaining a safe home requires investment, both in time and money. But after responding to families who’ve been poisoned by CO, I can tell you that no amount of money is worth risking your family’s life.

Call me today at (651) 403-6300 for immediate CO testing and heat exchanger inspection. Don’t wait until you’re feeling sick or your CO detector goes off. By then, you’ve already been exposed to dangerous levels of carbon monoxide.

I’m available 24/7 because carbon monoxide doesn’t wait for business hours. When you call, you’re talking directly to me, not an answering service. I’ll be at your door within 30 minutes with everything I need to test your home and inspect your heat exchanger.

Your family’s safety is worth one phone call. Make it now.