What to do when an HVAC installation fails inspection
Bad HVAC installations often involve dangerous issues like gas leaks, missing thread compound, uninsulated ducts, and mismatched or outdated equipment. These critical safety code violations and missing warranties leave homeowners dealing with failed inspections, hazardous living conditions, and unresolved cleanup costs.
What the numbers show
Counted from the threads quoted below. How we count
- The most recent one is from October 2026.
- This comes up 24.7× more often in r/hvacadvice than across the site as a whole.
What people tried
Every workaround mentioned in the threads below. We haven’t tested any of them — and nobody here is claiming they worked.
Found another way around this?
Share your steps and trade-offs so fellow engineers don't have to reinvent the wheel. No account required.
- 1Buying a different size filter and trying to cover the opening with tapeDid this help you?
- 2Calling the original installers back to ask questionsDid this help you?
- 3changing the crossover duct independentlyDid this help you?
- 4checking system pressures, subcool, and superheatDid this help you?
- 5attempting to register the equipment online to check warranty statusDid this help you?
- 6Used insulation foam and insulation tape to seal the feed tube under the window panelDid this help you?
- 7Added a layer of white duct tape and a lace curtain to hide the installationDid this help you?
- 8Used the condensate to water plantsDid this help you?
- 9Calling a reputable company to assess the situationDid this help you?
- 10Threatening legal action or demanding a full refundDid this help you?
- 11Having family members present during confrontations with the contractorDid this help you?
- 12Having the company measure the space and fit the heat pump with a baffle to direct air upwardsDid this help you?
- 13researching the issue independentlyDid this help you?
- 14calling professionals to identify the causeDid this help you?
- 15Using brass adapters at the outdoor unit to connect larger pipes to smaller portsDid this help you?
- 16Replace water heater with a power vented tankDid this help you?
- 17Replace fresh air pipe with hrvDid this help you?
- 18Tape up all exposed return duct joints and holes with tin tapeDid this help you?
- 19Use a sheet metal door or tape over the filter opening to help seal it upDid this help you?
- 20Shut the furnace fan off when appliances like dryers or bath fans are runningDid this help you?
- 21Draining the condensate line into the basement perimeter drainDid this help you?
- 22Running lines through wood framing instead of the foundationDid this help you?
- 23Making things work temporarily or bypassing best practices.Did this help you?
- 24Knocking the component back into place or fixing minor installation oversights oneself.Did this help you?
- 25Calling the HVAC company back to fix the issuesDid this help you?
- 26Inspecting the attic, filter, and drain pan personallyDid this help you?
- 27Using high temp silicone caulk to seal gapsDid this help you?
- 28Calling other HVAC companies for helpDid this help you?
- 29Checking with inspectors regarding code requirements and grandfathered installationsDid this help you?
- 30putting a grille in the floorDid this help you?
- 31extending the return air duct in the basement ceiling to reach another wallDid this help you?
- 32engaging professionals to validate a repair planDid this help you?
- 33Waiting until Monday for technical support to resolve software configuration issuesDid this help you?
- 34Relying on cool weekend weather to manage without working AC temporarilyDid this help you?
- 35Trying to determine what is purely cosmetic versus what actually matters functionallyDid this help you?
- 36Applying silicone yourself to seal air gapsDid this help you?
- 37Deciding whether to call the installation company back to request touch-upsDid this help you?
- 38filling up the p trap with waterDid this help you?
- 39calling the installation company back to address issuesDid this help you?
- 40adding a ventilation grille to the doorDid this help you?
- 41raising the unit up off the wood blocksDid this help you?
- 42Replacing the refrigerantDid this help you?
- 43Purchasing own R-410a refrigerant or hiring another company to refill the system after repair.Did this help you?
- 44Calling the contractor back to fix the installationDid this help you?
- 45Having the work inspected by local building code authoritiesDid this help you?
- 46Replacing flexible lines with hard pipe and unionsDid this help you?
- 47Getting multiple installation proposals beforehandDid this help you?
- 48Bringing issues up to apartment managementDid this help you?
- 49Documenting defects on the inventory and condition formDid this help you?
- 50Asking online communities for advice on whether an installation is safeDid this help you?
- 51Inspecting the unit directly for missing tape, air leaks, or frozen coils.Did this help you?
- 52Posting photos of the unit online to get a second opinion from other professionals.Did this help you?
- 53Calling the original company back to demand a free secondary diagnostic visit.Did this help you?
In their words
Unedited, grouped by where they were said, most upvoted first within each place, each linked to the thread it came from.
“I DID NOT INSTALL THIS!! MY LANDLORD DID! thanks for the help in coming up with a temporary solution to this disaster mini split in my rental room.”source ↗
“The first day, last week, they installed our new 5 ton system, they ran out of r32 and it shut itself off from the safety switch.”source ↗
“Since then, the handler runs normally for about 30 mins or so then will sound like it’s powering down like it’s about to turn off, then ramps back up.”source ↗
“Today I got home and found my ceiling dripping. Went to the attic and it’s a giant wet mess.”source ↗
“3 canvas connectors!”source ↗
“So I just moved into an apartment and I noticed/ heard condensate dripping onto the top of the water heater.”source ↗
“A Company installed the new furnace a few months ago and one of the installers did this. I went in and the system was kicking on and off. 🤷♂️”source ↗
“The previous setup had the drain pan draining into the drain line, and the tradesman capped it off and said that is what he always does, and I kind of took it at his word, but the more I thought about it, the more I wonder why you would put in a drain and then cap it”source ↗
“My air conditioning unit is constantly sweating, and the filter is generally wet, as well as the wood in the picture is wet to the touch, almost 3/4 up, so it’s obviously absorbing water.”source ↗
“The HVAC company has assured me that this is normal, but I don’t remember having any other air conditioning unit inside or outside where I constantly had water dripping through the filter, and I’m worried about mold on the wood or the filters.”source ↗
“I just see a lot of things in the set up that maybe could’ve been a little bit more cosmetically pleasing, or that maybe shows that a little less care was done, or maybe it’s just that they did the bare minimum”source ↗
“Blatantly illegal where i am. Ontario Canada”source ↗
“Looks like something my 4 year old would make as a art project”source ↗
“AC starts to short-cycle”source ↗
“Co2 alarm starts blaring!! Cats are running up the walls and I'm 😡.”source ↗
“Water is seeping up from under our one year old floor and I hear dripping behind the return air register.”source ↗
“He admits to: not being a licensed electrician, not doing the load calculations to determine the correct tonnage for house and claims that he did it to save us money.”source ↗
“I see metal threads going into plastic threads. If that is indeed plastic, it will let go eventually”source ↗
“Hey long story long I had an HVAC tech come replace my thermal expansion valve after my AC never being able to reach set thermostat temp. There was reprieve for a couple days but then same thing was happening again.”source ↗
“He came back and said he forgot to tighten something (was here for about an hour). Couple days later and here I am in the same boat as before.”source ↗
“I go to my attic to look at the unit and notice air coming out of a lot of areas (cracks, holes etc). And I know for a fact that wasn’t the case when I checked the attic before calling the tech the 1st time.”source ↗
“I recently just hired a pretty well google-rated HVAC company to replace my 18-year old central AC in NYC. But it has proven to be quite a headache.”source ↗
“So, I was quite alarmed to see that my new heat pump is currently just 13 inches away from my neighbor's, blowing hot air directly into it.”source ↗
“Now my concern is how it will affect my unit. Will a baffle cause static pressure that will just ruin my system over time? Is there any other solution to my current problem given this set up?”source ↗
“There’s no return vent inside my condo. The previous owner replaced this 2 years ago and had been living like this with no return vent. It stinks inside and very humid.”source ↗
“Because of where the combustion air intake is attached to the HVAC I think I'm getting consistently cold air pulled into the HVAC around the filter.”source ↗
“I'm not sure if I didn't just give myself another problem to deal with. Should this have been installed elsewhere?”source ↗
“Had reputable company installing mini split system today (they'll be back tomorrow to finish) and just noticed that they drilled through my 125 year old brick foundation right under the sill plate for the condensate line.”source ↗
“What's the best way to handle this now? I'm mostly concerned about longer term structure or foundation problems.”source ↗
“looks like shit and prolly leaks too”source ↗
“We had replaced both our cooling and heating units a few months ago. I do not remember it looking so alarming when they were finished. Is this a "get it looked at ASAP" kind of issue?”source ↗
“This is not correct, right? The opening in the floor of the second return is far too small to adequately return air, correct?”source ↗
“The return duct shouldn't just be open to the basement ceiling, either, right?”source ↗
“Would love some feedback or suggestions regarding how to proceed here. I am way out of my element, as I have never had to replace an HVAC system before.”source ↗
“Started Friday with a semi working upstairs A/C unit, ended with a nonfunctioning new unit that won't be operational until Monday...”source ↗
“By this point it was too late to stop him (and I'm a novice homeowner at this so I don't have a complete understanding of the system), but that sounded like BS to me. Am I wrong? How should I handle this? Was this just a lazy tech who didn't want to get a tank to retrieve the refrigerant.”source ↗
“Looks like shit. No drip leg after the shut off valve, sloppy appliance connector, ran the stub out through PVC and caulked it so hopefully there’s no leaks in there.”source ↗
“I have until tomorrow to sign the inventory and condition form for any defects or damage in my apartment.”source ↗
“The inspector failed the install because of a gas leak in the furnace.”source ↗
“One of the galvanized pipes supplying gas had no thread compound or tape on it.”source ↗
“I have what I believe is fiberglass dust that has settled on my furniture.”source ↗
“They gave him a brand new 3-5 ton indoor electric air handler & a 5 year old 410-A condenser. They also didn’t change the metal uninsulated crossover duct underneath the house.”source ↗
“On top of all this he has a basic 5 year warranty , I’m guessing because the don’t give a 10 year warranty on 5 year old equipment? Or they didn’t do the warranty all together?”source ↗
“The bottom part where the filter replacement is should be facing the other way so I can change the filter inside, not outside.”source ↗
“I contacted the guy who installed it, he came to change it, but had a problem with the last connection to the vent that goes up through my roof.”source ↗
“You can see in the pics that the connection is not right and I don’t want to risk CO leaking in my house as a result of faulty work but I don’t want to call the first guy back out.”source ↗
“He has spent lots of hours and still didn’t get it right.”source ↗
“When I call other companies what should I ask? What should I expect? I just want it done right at this point.”source ↗
“Had a new Lennox EL296V installed yesterday. It seems to be running fine, but I noticed a few things that look a little off.”source ↗
“There are some gaps in the ductwork where I can feel warm air leaking out, a few screws sticking through the supply duct, the sheet metal above the furnace hangs past the edges, and the humidifier looks a bit too big for the duct with a visible gap in one spot.”source ↗
“Is this pretty normal for an install, or should I get the installer back to clean some of this up?”source ↗
“Just trying to figure out what’s cosmetic and what actually matters.”source ↗
“Noise is so loud and concerning I can’t enjoy being home.”source ↗
“Worst part? The lines are already buried in concrete. Ripping them out is 100% off the table unless I take a sledgehammer to my floors.”source ↗
Where this came up
People with this problem also raised
- 4Can you service an HVAC system with leak seal in it?
- 46Why does my new plumbing still have bad water pressure and risky joints?
- 7Are open cavity vent returns and exposed pipes normal in new construction?
- 6New HVAC unit won't heat and makes clicking sounds
- 30Why are HVAC replacement quotes so expensive?
- 3Why a clogged drain line diagnosis doesn't make sense