Day & Night Internal Corrosion / Condensate Misrouting

Rust or water stains visible inside the burner compartment or on the heat exchanger surfaces.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Improper condensate drainage, flue gas condensation in non-condensing furnace, leaking humidifier, high humidity in furnace room

How to Fix / Troubleshooting

Safety first: Corrosion on the heat exchanger can lead to dangerous flue gas leaks. Do not ignore this condition.

  • Inspect condensate routing: Ensure condensate lines are connected to the proper ports and not dripping onto the heat exchanger or burners.
  • Check humidifier: If a bypass or powered humidifier is attached, inspect for leaks and proper drainage.
  • Dry area: Address any standing water or high humidity sources near the furnace.

A corroded heat exchanger must be inspected by a licensed technician. Replacement of the heat exchanger or furnace may be required.

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Repair Difficulty

Professional Required 5/5

Required Part

Primary Heat Exchanger
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