Replacing a 5-ton AC unit and furnace is a significant investment for American homeowners seeking comfort and energy efficiency. Costs vary due to system type, installation complexity, and regional factors. This in-depth guide highlights replacement costs, installation tips, brand considerations, and cost-saving strategies to help you make an informed decision in 2025.
| Factor | Description | Estimated Cost Range |
|---|---|---|
| Equipment (5-Ton AC + Furnace) | Price for standard vs. high-efficiency systems | $7,000 – $12,500 |
| Installation Labor | Professional installation by HVAC technicians | $2,500 – $5,000 |
| Additional Materials/Upgrades | Thermostats, ductwork, permits, removal of old units | $800 – $3,000+ |
| Total Average Cost | Turnkey replacement project estimate | $10,000 – $20,000+ |
What Is A 5-Ton AC Unit And When Is Replacement Needed?
A 5-ton AC unit offers 60,000 BTUs of cooling power, suitable for homes around 2,500 to 3,500 square feet, depending on insulation and climate. Such a unit is often paired with a matching high-capacity furnace for heating. Replacement is typically required when existing systems are over 15 years old, experience frequent breakdowns, consume excess energy, or no longer maintain indoor comfort. Upgrading offers efficiency improvements, environmental benefits, and long-term cost savings.
Average Cost Breakdown For Replacing 5-Ton AC And Furnace
The cost to replace both a 5-ton air conditioner and furnace ranges widely due to equipment efficiency, brand, and installation complexity. Here’s a detailed breakdown:
- Standard Efficiency Systems (14–16 SEER AC, 80–90% AFUE Furnace): $10,000–$15,000 installed
- High-Efficiency Systems (18+ SEER AC, 95–98% AFUE Furnace): $14,000–$20,000+ installed
- Labor Only: $2,500–$5,000 (region & project dependent)
- Permits & Removal/Disposal Old Units: $300–$800
- Ductwork Modifications/Upgrades: $1,000–$3,000+
Premium systems offering zoning, advanced air filtration, and smart thermostats typically cost more, while basic replacements in accessible homes tend to be less expensive.
Key Cost Factors For 5-Ton AC And Furnace Replacement
Several variables influence the final price of a 5-ton AC and furnace installation:
- Equipment Efficiency & Brand: High-efficiency or premium-brand units cost more upfront but yield significant long-term energy and maintenance savings.
- Home Size & Layout: Larger, multi-story, or complex homes may require additional ductwork or zoning.
- Existing Infrastructure: If major duct, electrical, or gas line upgrades are needed, project costs rise.
- Installation Accessibility: Tight attics, basements, or roof mounting generally increase labor time and cost.
- Climate Region: Hot or cold climates may require specialized systems, impacting cost.
- Permitting & Local Code Compliance: Local codes vary and may require specialized labor or fees.
Popular Brands For 5-Ton AC And Furnace Combos
A few HVAC brands are known for reliable, efficient 5-ton residential systems. Homeowners typically select from the following:
- Trane / American Standard: Known for robust construction and dependable performance.
- Carrier / Bryant: Leaders in innovation and quiet operation.
- Lennox: High-efficiency and environmentally friendly options.
- Rheem / Ruud: Value-forward with solid warranties.
- Goodman / Amana: Budget-friendly and widely available.
Prices often reflect brand reputation, quality, and the offered warranty. Extended warranties and labor guarantees can add value to your investment.
How Sizing And Efficiency Impact Replacement Costs
Properly sizing your HVAC system is crucial for both cost and comfort. Oversized or undersized systems waste energy and reduce lifespan. A reputable contractor will perform a Manual J load calculation to determine the ideal capacity for your home.
- SEER (Seasonal Energy Efficiency Ratio) for AC: The higher the SEER, the more energy efficient the system, but upfront costs rise.
- AFUE (Annual Fuel Utilization Efficiency) for Furnace: The higher the AFUE, the more heat the furnace supplies for every dollar spent on fuel.
A balance between efficiency and upfront investment often yields the best long-term value.
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Detailed Installation Process For 5-Ton Complete HVAC Systems
Professional installation is key to safe, efficient operation and maintaining warranties. The installation process generally includes:
- Assessment of home layout and measurement of load requirements.
- Removal and disposal of existing air conditioner and furnace units.
- Preparation of location, including electrical, refrigerant, and gas lines.
- Setting and securing new furnace and condenser units.
- Connecting ductwork, wiring, and fuel lines as necessary.
- Testing, system calibration, and final inspection for proper function.
- Permit approval and customer walkthrough.
Proper installation minimizes future repair costs and maximizes equipment lifespan.
Permitting And Code Requirements
Most municipalities require permits for HVAC replacements. These permits help ensure safe, code-compliant installation. Contractors usually handle the permit process, which can affect the replacement timeline and cost.
- Permit fees: $100–$600, depending on locality
- Inspection requirements: Electrical, gas, and mechanical inspections may be necessary
Homeowners should verify contractors are licensed and insured to protect against liability and guarantee workmanship.
Cost Comparison: Repair vs. Replacement
| Scenario | Estimated Cost | Best Option |
|---|---|---|
| Minor AC or furnace repair | $300–$1,200 | Repair |
| Major heat exchanger or compressor replacement | $2,000–$4,500 | Consider replacement if system is older than 10 years |
| Multiple system failures or high energy bills | $4,000–$6,000 (accumulated repairs) | Replace with more efficient system |
Generally, if the system is beyond 10–15 years old, or repair costs reach 50% of a new system, replacement is recommended for increased value and reliability.
Energy Efficiency Rebates And Tax Credits
Many states and utilities offer rebates or tax credits for upgrading to high-efficiency HVAC systems. Under the federal Inflation Reduction Act (IRA) and state energy programs, incentives often include:
- Federal tax credits up to $600 for qualifying air conditioners and $600 for qualifying furnaces
- Utility company rebates typically between $100–$1,200
- Special low-interest HVAC financing or on-bill utility financing
Check eligibility and documentation requirements, as rebates may require certified installation and specific SEER or AFUE ratings.
Cost Saving Strategies For Homeowners
There are several ways to reduce your overall cost of replacing a 5-ton AC and furnace:
- Request multiple bids from licensed, reputable contractors
- Time your project for the spring or fall “off-season” when HVAC demand is low
- Consider financing or payment plan options
- Upgrade insulation and seal ducts to minimize required system size
- Bundle AC and furnace replacement versus piecemeal replacement
Taking steps to improve your home’s energy efficiency can enable the use of smaller, less expensive HVAC systems.
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Financing Options For HVAC Replacement
Given the significant investment, many contractors and financial institutions offer HVAC financing solutions:
- Zero-interest or low-interest payment plans through the contractor
- Secured or unsecured home improvement loans
- FHA Title I loans dedicated specifically to home systems
- Utility company on-bill financing (where available)
Financing can spread the cost over several years, making high-efficiency upgrades more accessible to homeowners.
Choosing The Right Contractor For HVAC Replacement
Proper system sizing and installation quality play a greater role than equipment brand in the longevity and efficiency of your new system. For the best results:
- Obtain at least three written estimates for comparison
- Verify licensing, insurance, and experience with 5-ton systems
- Ask for references and reviews from recent clients
- Confirm warranty details (labor and equipment)
- Avoid contractors who quote prices without a proper home assessment
Quality workmanship often saves money over the long term by preventing premature failures and high energy bills.
Common Upgrades During 5-Ton HVAC Replacement
Replacing both the AC and furnace is an ideal time to enhance your home’s comfort and efficiency further. Popular upgrades include:
- Smart thermostats: Improve control and reduce energy waste
- Zoned heating/cooling: Direct airflow for more even comfort
- Advanced air filtration: Enhanced indoor air quality, important for allergy sufferers
- Variable speed blowers: More precise temperature and humidity control
- Ductwork resealing or replacement: Reduces heat loss and improves airflow
Discuss options and pricing with your contractor for a holistic upgrade.
Maintenance Tips To Extend The Life Of Your New System
Protect your investment and keep your new system running at peak performance with regular maintenance:
- Change air filters every 1–3 months
- Schedule annual professional inspections and tune-ups
- Keep outdoor condenser units clear of debris and foliage
- Ensure vents and registers are unobstructed
Most manufacturers require documented maintenance for the warranty to remain valid.
5-Ton HVAC Replacement: Frequently Asked Questions
- How long does replacement take? Typically 1–3 days, including removal and installation.
- Is it more cost-effective to replace both AC and furnace together? Yes, doing both simultaneously saves on labor and ensures system compatibility.
- Do I need to replace my ductwork too? Not always, but if it’s undersized, leaky, or dirty, upgrades are recommended
- How can I verify the system is sized correctly? Request a Manual J load calculation from your contractor
Summary Table: 2025 Cost To Replace 5-Ton AC Unit And Furnace
| Component/Factor | Average Price (Low-End) | Average Price (High-End) |
|---|---|---|
| Equipment (AC & Furnace) | $7,000 | $12,500 |
| Installation/Labor | $2,500 | $5,000 |
| Permits/Removal/Disposal | $300 | $800 |
| Ductwork/Upgrade Materials | $1,000 | $3,000+ |
| Total | $10,000 | $20,000+ |
Replacing a 5-ton AC unit and furnace is a major home upgrade with costs reflecting efficiency, installation quality, and regional variations. Thorough planning, proper contractor selection, and leveraging available rebates ensure the best long-term comfort and value for your investment.
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