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I don't think mine is rusted out, bobbyj, and I don't have the smell issues, but I understand the secondary on these can get plugged with algae and condensate. Is yours upflow, downflow, or horizontal? I haven't had mine apart, but the clear line to the pump is pretty clean, and I'm hoping I won't have to tear into the exchangers. If you have that problem, I would vacuum clean your primary for soot while you're in there, and run some ammonia or alcohol through the line to clean that. Just don't cut your plastic exhaust line.
Have you been through any control cards? Mine ate one in the first five years while it was still under warranty, then another one last winter, which I tore apart and filed the relay contacts, putting it back in service. I still have it for a test card, but replaced it in November with an ICM generic.
The inducer blower motor bushing is absorbing some of that lubricant now, and I used the furnace for a 2 degree cycle this morning to take the chill off, then bumped it another degree and it held, so I figure the that motor overheating was tripping the aux reset. I left it off and burned wood today, but I'll probably let it run a little longer tomorrow morning and see what happens.
Thanks for the parts source, Hayzee. If this thing doesn't complain I'll probably wait until summer.
Alley Oop
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