Said It Here

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often involve dangerous issues like gas leaks, missing thread compound, uninsulated ducts, and mismatched or outdated equipment.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.

Overview
People affected28 accounts across 2 forums
Workarounds found53 items attempted
Community agreement192 total upvotes

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.

53 items+ Contribute

Found another way around this?

Share your steps and trade-offs so fellow engineers don't have to reinvent the wheel. No account required.

  1. 1
    Buying a different size filter and trying to cover the opening with tape
    Did this help you?
  2. 2
    Calling the original installers back to ask questions
    Did this help you?
  3. 3
    changing the crossover duct independently
    Did this help you?
  4. 4
    checking system pressures, subcool, and superheat
    Did this help you?
  5. 5
    attempting to register the equipment online to check warranty status
    Did this help you?
  6. 6
    Used insulation foam and insulation tape to seal the feed tube under the window panel
    Did this help you?
  7. 7
    Added a layer of white duct tape and a lace curtain to hide the installation
    Did this help you?
  8. 8
    Used the condensate to water plants
    Did this help you?
  9. 9
    Calling a reputable company to assess the situation
    Did this help you?
  10. 10
    Threatening legal action or demanding a full refund
    Did this help you?
  11. 11
    Having family members present during confrontations with the contractor
    Did this help you?
  12. 12
    Having the company measure the space and fit the heat pump with a baffle to direct air upwards
    Did this help you?
  13. 13
    researching the issue independently
    Did this help you?
  14. 14
    calling professionals to identify the cause
    Did this help you?
  15. 15
    Using brass adapters at the outdoor unit to connect larger pipes to smaller ports
    Did this help you?
  16. 16
    Replace water heater with a power vented tank
    Did this help you?
  17. 17
    Replace fresh air pipe with hrv
    Did this help you?
  18. 18
    Tape up all exposed return duct joints and holes with tin tape
    Did this help you?
  19. 19
    Use a sheet metal door or tape over the filter opening to help seal it up
    Did this help you?
  20. 20
    Shut the furnace fan off when appliances like dryers or bath fans are running
    Did this help you?
  21. 21
    Draining the condensate line into the basement perimeter drain
    Did this help you?
  22. 22
    Running lines through wood framing instead of the foundation
    Did this help you?
  23. 23
    Making things work temporarily or bypassing best practices.
    Did this help you?
  24. 24
    Knocking the component back into place or fixing minor installation oversights oneself.
    Did this help you?
  25. 25
    Calling the HVAC company back to fix the issues
    Did this help you?
  26. 26
    Inspecting the attic, filter, and drain pan personally
    Did this help you?
  27. 27
    Using high temp silicone caulk to seal gaps
    Did this help you?
  28. 28
    Calling other HVAC companies for help
    Did this help you?
  29. 29
    Checking with inspectors regarding code requirements and grandfathered installations
    Did this help you?
  30. 30
    putting a grille in the floor
    Did this help you?
  31. 31
    extending the return air duct in the basement ceiling to reach another wall
    Did this help you?
  32. 32
    engaging professionals to validate a repair plan
    Did this help you?
  33. 33
    Waiting until Monday for technical support to resolve software configuration issues
    Did this help you?
  34. 34
    Relying on cool weekend weather to manage without working AC temporarily
    Did this help you?
  35. 35
    Trying to determine what is purely cosmetic versus what actually matters functionally
    Did this help you?
  36. 36
    Applying silicone yourself to seal air gaps
    Did this help you?
  37. 37
    Deciding whether to call the installation company back to request touch-ups
    Did this help you?
  38. 38
    filling up the p trap with water
    Did this help you?
  39. 39
    calling the installation company back to address issues
    Did this help you?
  40. 40
    adding a ventilation grille to the door
    Did this help you?
  41. 41
    raising the unit up off the wood blocks
    Did this help you?
  42. 42
    Replacing the refrigerant
    Did this help you?
  43. 43
    Purchasing own R-410a refrigerant or hiring another company to refill the system after repair.
    Did this help you?
  44. 44
    Calling the contractor back to fix the installation
    Did this help you?
  45. 45
    Having the work inspected by local building code authorities
    Did this help you?
  46. 46
    Replacing flexible lines with hard pipe and unions
    Did this help you?
  47. 47
    Getting multiple installation proposals beforehand
    Did this help you?
  48. 48
    Bringing issues up to apartment management
    Did this help you?
  49. 49
    Documenting defects on the inventory and condition form
    Did this help you?
  50. 50
    Asking online communities for advice on whether an installation is safe
    Did this help you?
  51. 51
    Inspecting the unit directly for missing tape, air leaks, or frozen coils.
    Did this help you?
  52. 52
    Posting photos of the unit online to get a second opinion from other professionals.
    Did this help you?
  53. 53
    Calling the original company back to demand a free secondary diagnostic visit.
    Did this help you?
Tried another approach not listed above?+ Share your workaround ↑

In their words

Unedited, grouped by where they were said, most upvoted first within each place, each linked to the thread it came from.

r/hvacadvice27 people · September 2026 – October 2026

“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 ↗

nightmare___fruits · r/hvacadvice · 112 upvotes

“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 ↗

Life-uhfindsaway · r/hvacadvice · 18 upvotes

“3 canvas connectors!”source ↗

Reasonable_Floor_704 · r/hvacadvice · 9 upvotes

“So I just moved into an apartment and I noticed/ heard condensate dripping onto the top of the water heater.”source ↗

gogo-lizard · r/hvacadvice · 9 upvotes

“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 ↗

Inevitable-Staff5786 · r/hvacadvice · 8 upvotes

“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 ↗

Hallsie11 · r/hvacadvice · 7 upvotes

“Blatantly illegal where i am. Ontario Canada”source ↗

Necessary_Case_1451 · r/hvacadvice · 4 upvotes

“Looks like something my 4 year old would make as a art project”source ↗

Cumofoneyounguy · r/hvacadvice · 4 upvotes

“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 ↗

Necessary-Mission-48 · r/hvacadvice · 3 upvotes

“I see metal threads going into plastic threads. If that is indeed plastic, it will let go eventually”source ↗

FloodAdvisor · r/hvacadvice · 3 upvotes

“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 ↗

plencoolilikeplen · r/hvacadvice · 3 upvotes

“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 ↗

Content-Swan-5578 · r/hvacadvice · 1 upvotes

“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 ↗

Pikachuu0711 · r/hvacadvice · 1 upvotes

“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 ↗

ParticularAd3247 · r/hvacadvice · 1 upvotes

“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 ↗

encouragingSN · r/hvacadvice · 1 upvotes

“looks like shit and prolly leaks too”source ↗

Cute_Intention_9864 · r/hvacadvice · 1 upvotes

“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 ↗

Rosefier · r/hvacadvice · 1 upvotes

“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 ↗

sbattistella · r/hvacadvice · 1 upvotes

“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 ↗

atari2600forever · r/hvacadvice · 1 upvotes

“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 ↗

Occipital_Engineer · r/hvacadvice · 1 upvotes

“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 ↗

greenday9261 · r/hvacadvice · 1 upvotes

“I have until tomorrow to sign the inventory and condition form for any defects or damage in my apartment.”source ↗

gogo-lizard · r/hvacadvice · 1 upvotes

“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 ↗

Correct-Brother1776 · r/hvacadvice

“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 ↗

CBunivers3 · r/hvacadvice

“The bottom part where the filter replacement is should be facing the other way so I can change the filter inside, not outside.”source ↗

Pikachuu0711 · r/hvacadvice

“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 ↗

2002diva · r/hvacadvice

“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 ↗

HedgehogBoring5679 · r/hvacadvice

“Noise is so loud and concerning I can’t enjoy being home.”source ↗

bkressm · r/hvacadvice

“the new HVAC cabinetry is horribly done.”source ↗

“she cant close the lid because it doesnt line up with the hole its supposed to go into and it doesnt fit together properly.”source ↗

Tressa_330 · r/hvacadvice
r/Plumbing1 person · September 2026

“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 ↗

Failed_engineer22 · r/Plumbing · 1 upvotes

“I physically measured the connection ports on the machines and they don't match:”source ↗

“My installer already ran the copper lines in the wall. Because of the mixed sizes, he ran a 1/4" pipe for the liquid line and a 5/8" pipe for the gas line.”source ↗

Failed_engineer22 · r/Plumbing

Where this came up

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