A homeowner in Wake Forest called us about a furnace that wouldn't stay on — runs for a few minutes, shuts down, then fails to relight. Another company had already been out and recommended replacement with a "cracked heat exchanger" diagnosis. The quote was just under $7,500.
We came out with a $72 diagnostic. Heat exchanger inspected with a borescope camera, flame characteristics observed, combustion analyzed, gas pressure verified at the manifold. The heat exchanger was intact — no crack, no soot pattern, no flame rollover.
What was actually wrong: the hot-surface igniter was on its last legs, lighting some cycles and failing others. The flame sensor was also coated with combustion residue, which can mimic a "system shutting down for safety" pattern.
The igniter was replaced and the flame sensor cleaned on the same visit, the $72 diagnostic credited toward the work. The furnace ran through the rest of the winter without an issue.