The drip pan in my 16-year old York A/C is rusty and needs to be replaced at a cost of $850. The original installer says it isn't worth it and recommends replacing the air handler at a cost of $3800. He said we can wait until the condenser fails before replacing it.
A second company suggested replacing the entire system (air handler and condenser) for $9000+. According to the salesman, a replacement air handler would have to be an R22. When I later replace the condenser with an R410, I'll have to replace the air handler again.
So, who should I believe? Also, what is the expectant life of an AC system? Perhaps it's worth spending the $850 to replace the pan.

A 16 year old system is nearing its later life. A good equation you can use is is RV=EA x CR > $4000. This means the Replacement value = Equipment Age x Cost of Repair is less than $4000.
So in your case 16 x $850 = $13,600. Not less than $4000 so it is a very good idea to consider replacing entire system. Do not put in R22 system. The manufacturers aren't even making R22 units anymore. Plus the efficiency you are going to gain from 410A will be noticeable. Yes the contractor is right... if you replace just the a.h. then when you replace condensing unit you would have to replace a.h. again because of the refrigerant differences. $3800 for an air handler seems pretty high! If you replace the entire system with a 16-19 seer system you could spend between 7000 and 12000. Depending on efficiencies etc. Most manufacturers carry a 10 year parts and labor warranty so that would be some value too. You could replaced the drain pan and then a week later your compressor on your condensing unit could fail and then you are talking $2000 for that and a 1 year warranty on compressor. Check with your power company for any incentives they give if you put in a heat pump system with certain seer rating. Also some manufacturers have special promos like cash back or free financing. Hope this helps.

Thanks folksatnoakes.

I just had a third estimate. This person came highly recommended, and he agrees with what you are saying. He suggested replacing the entire system with SEER 16. He is offering a 10 warranty on labor and material backed by the manufacturer. This will also qualify for over $1,000 in power company incentives and Federal Tax credits. He also said I should have a considerable saving in my electric bill because of the higher efficiency.
I still want to contact the original installer. I need to understand why he recommended replacing just the air handler. It seems like very bad advice.

Unfortunately some contractors really don't have customers best interest when making suggestions. And some make the mistake that you wouldn't replace the entire system or they are so backed up that they wouldn't have time to get to you in a timely fashion. Great I hope all goes well for you.

:p
Good idea about talking to the original tech. Find out if he was going to change just the evap coil, the hole air handler, or what for 850. Also, find out what exactly he planned on replacing for 3800. The air handlers I have dealt with come in two parts. The air handler itself, (blower, and controls) and the evap coil is an add on (seperate cased coil that mounts to the air handler.) Depending on the brand of unit you planned on buying, you could possibly get the air handler, evap coil, line set, condenser, all 410a installed for under 5000 , (at least in my area where we don't hike the rates to ungoddly proportions). This is all assuming that the air handler isn't actually a forced air furnace, but just an air handler. And of course assuming that the installer is near by, not 100 miles out. Travel time, mileage, etc etc all come into play, and can add up in a hurry.

Over all, Im in complete agreement with folks. With the phasing out of R-22, and the takeover of R-410, your best bet would be to get the complete system changed out to 410a. If you just don't have the funds, and want to roll the dice, you could have just the evap coil changed (cant change just the drain pan on most coils, have to replace the complete coil/drainpan assembly). If you can find a way to afford it, bite the bullet and have the new "techology") installed (410a). With any luck it will be around and available for at least five years before the next best things comes along and pushes it to the side,, :p

The way things have changed with refrigerants in the last couple decades, I wouldn't be surprised to see an R-299339020-1--20939990zz by the time I expire, or retire, whichever comes first.

I just had a phone conversation with the original installer (I have also been using him for annual inspection/maintenance). He is going to work up some numbers and come over next week so that we can discuss the options.

I asked him why he recommended just changing the air handler at this time. He said that there are air handlers that work with R22 and R410A, and there would be no problem installing an R410A condenser later on. Does anyone agree with him? I thought that this would involve different pipe sizes, pressure ratings, etc. that would increase the price.

At this point, replacing the entire system (air handler, condenser, etc.) makes more sense to me. The question is if the original installer is being forthright with me so that I should continue doing business with him. Any thoughts?

What did you end up replacing for the A/C? Your last post was almost 1 year ago. I am in a similar pridicament and I need to decide if I replace the condenser with an R22 or replace the whole system with the newer R410A. Wondering how it worked out for you.

Thanks!