Tappan Condensate Backflow into Heat Exchanger

Rust or water stains inside the burner compartment of a high-efficiency Tappan furnace.

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

Blocked condensate drain, improper vent slope, deteriorated condensate hoses, secondary heat exchanger restriction

Safety: Turn off power and gas. Rust inside the burner area can indicate long-term condensate issues.

Steps:

Inspect and clear the condensate drain and trap as described in the condensate leak entry.
Check that the PVC vent pipe slopes back toward the furnace per Tappan installation instructions, allowing condensate to drain properly.
Replace any soft or collapsed condensate hoses.
If rust is extensive or the secondary heat exchanger appears plugged, have a technician evaluate for heat exchanger replacement.

Professional Required 5/5

Secondary Heat Exchanger

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