Ducane Internal Corrosion from Condensate or Flue Gases

Rust-colored water or corrosion visible inside furnace cabinet

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.

Possible Causes

Chronic condensate leaks, Improper venting causing flue gas condensation, Cracked secondary heat exchanger on Ducane condensing furnace, Failed condensate trap seals

How to Fix / Troubleshooting

Safety first: Turn off power and gas. Corrosion can compromise safety-critical components.

Step 1 – Identify moisture source: Inspect condensate lines, trap, and internal pans for active leaks.
Step 2 – Check venting: Ensure PVC vent joints are properly glued and sloped, and that terminations are correct per Ducane instructions.
Step 3 – Do not ignore heavy corrosion: Significant rust on the heat exchanger or burners requires professional evaluation for replacement.

Repair Difficulty

Hard 4/5

Required Part

Condensate Trap Assembly

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