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I have only seen sweating PVC vent pipes on high efficiency furnaces on ones that were imporperly installed either without the proper slope as the manufacture recommends or the unit is oversized. If you get a high efficiency furnace and ever do need to change it out, you would have to go with another high efficiency furnace. But then again, if the DOE steps up on furnaces as they have with a/c and heat pumps for January 2006, it may be a non-issue in 10 years. As for the cost of replacing a heat exchanger, it is true that unless you have a parts AND labor warranty, the cost of labor is not covered under repairs. Labor is most generally only covered under the first year of a manufactures standard warranty. That even goes for the units with lifetime compressor and heat exchanger warrantys that offer a whole new furnace or a/c (not just the part that failed). In most cases (not all, there are always exceptions) the labor to change a heat exchanger shouldn't exceed 1/3 the cost of a furnace. Now if it is in a small crawlspace or up in an attic, or suspended above a false ceiling or on a rooftop then yes, you could expect some additional labor.
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