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New Furnace Installation Question

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  • Oct 29th, 2018 7:09 pm
[OP]
Sr. Member
Sep 7, 2017
888 posts
787 upvotes

New Furnace Installation Question

Hi all,

I recently had a new furnace installed to replace an 18 year old furnace. The new units are smaller in dimension and a plenum was added to join to the existing ductwork above. The return air duct curved boot is sticking out at the back, and taking a closer look see that there is a decent gap and the rear of the boot is not screwed into anything. It also wouldn't reach the collar from the new furnace and from what I can see the collar at the front is against the boot and screwed together. What is typically done to close the gap? A new boot? aluminum tape? Something to adapt the back of the boot with the collar of the furnace? It is the same 16x25x1 filter size that the old furnace has, but the old furnace extended further in the back and was a different design where you could reach in from the furnace to the return air with the filter removed. The new furnace is sealed cabinet. I don't see any screw holes in the back of the return duct/boot, so it probably wasn't screwed into the collar of the old furnace.

Hopefully my explanation provides a visual.... any advice or comments?

Thanks in advance.

Edit: Added photo
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Last edited by Bidjaan on Oct 28th, 2018 9:07 pm, edited 1 time in total.
6 replies
Deal Fanatic
User avatar
Oct 15, 2007
5275 posts
2714 upvotes
Bidjaan wrote: Hi all,

I recently had a new furnace installed to replace an 18 year old furnace. The new units are smaller in dimension and a plenum was added to join to the existing ductwork above. The return air duct curved boot is sticking out at the back, and taking a closer look see that there is a decent gap and the rear of the boot is not screwed into anything. It also wouldn't reach the collar from the new furnace and from what I can see the collar at the front is against the boot and screwed together. What is typically done to close the gap? A new boot? aluminum tape? Something to adapt the back of the boot with the collar of the furnace? It is the same 16x25x1 filter size that the old furnace has, but the old furnace extended further in the back and was a different design where you could reach in from the furnace to the return air with the filter removed. The new furnace is sealed cabinet. I don't see any screw holes in the back of the return duct/boot, so it probably wasn't screwed into the collar of the old furnace.

Hopefully my explanation provides a visual.... any advice or comments?

Thanks in advance.
Call the installer and ask them
Everything has been said before, but since nobody listens we have to keep going back and beginning all over again. - Andre Gide
[OP]
Sr. Member
Sep 7, 2017
888 posts
787 upvotes
I will be doing that. But wanted some advice to help me in the conversation.
Deal Addict
Dec 19, 2009
4700 posts
2602 upvotes
Have the installer fix it as it would act as a return intake and actually by code you can't have a return within 5' of the furnace.
[OP]
Sr. Member
Sep 7, 2017
888 posts
787 upvotes
Resolved today. Simple fix to unscrew, shift and reinstall boot. Turned out well and actually ended up making the duct plumb and aligned. Furnace is also running quieter. Thanks again.

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