10/18/06, 04:18 PM
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Join Date: Jun 2003
Location: Pa
Posts: 1,166
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You all are so helpful, thanks!! Here's an update... I'll do my best to explain further, but I'm not the one who worked on it so I hope I tell it right!
The transformer is relatively new-less than a year old. The nozzle is new & correct. The pump is less than five years old. Full tank of oil - filled after the problem started.
What it's doing is this: It starts up, runs, and shuts off just fine. But, it smells like fuel (To DH, to me it smells like burning plastic) from the ductwork/registers, we haven't let it run long enough (more than a minute) to see if smoke also comes through the ducts.
DH called around yesterday. A new unit, comparable to ours is around $1300. Installed our estimates ran from $3200 to $3600. We questioned the difference and was told by one guy that the installed price includes replacement of flue, fuel line, and any ductwork needed to connect the new unit.
Now, my question is this... DH is a very skilled auto mechanic. Very handy guy who pays attention and is very meticulous. Is it illogical to think that this is a job he can handle on his own? (with informed direction of course) If yes, what should he watch out for?
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Now, we've called two local repair guys with good reputations, but they haven't even taken the time to call back to set up an appointment even though I've called each one 2-3 times over the last 4 weeks. 
Seems they are still busy installing new furnaces to all the homes affected by the flood in June. So, DH has tried to diagnose/repair the thing himself and he's concluded that it's probably a cracked combustion chamber. 
RedTartan
