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Gas Pack Replacement Cost Range
The cost to hire a local HVAC company to install a new gas pack HVAC system at your home, ranges between $5,325 and $7,250. Many variables go into this price including: the unit size, location of the packaged unit (side of home or roof), efficiency, and much more.
The average cost of a gas pack unit installed is $6,775. The low price is about $3,800, and the most expensive gas packaged units are about $8,400 installed. These are direct replacement prices. If new ductwork or other major modifications are required, they will be additional costs.
This average cost includes: The packaged unit itself as well as removal and disposal of the old system. All installation and labor, reconnecting to existing duct with a new shield, warranty, and all permits and inspections as required.
Overview of Gas Package Units
A gas packaged unit contains a gas furnace and a central air conditioner in one large steel cabinet. They are also called gas packs or gas/electric packs or packed units.
This Costimate provides comprehensive pricing details, cost factors, costs from other estimate sites and prices supplied by homeowners that have had a gas pack installed. Being prepared is important when it comes to replacement of a high cost item like HVAC. Learn more about the most expensive home repairs, as well as how much to budget for unplanned home expenses.
Gas packaged units are typically installed where basements and crawl spaces aren’t common and in homes with limited space for equipment. They’re not as efficient as split system furnaces and central air conditioners and all components are subject to the elements. Gas pack cost for the equipment is lower than buying a separate AC and furnace. However, since they aren’t as efficient, operating costs are higher.
All price factors are explained on this page, so you’ll have a good ballpark estimate of what a gas packaged unit for your home should cost.
Gas Pack Cost Factors
Whether your cost will be closer to $4K or to $10K will depend on these factors.
- Energy Efficiency – There isn’t a large range of options. SEER rating options for air conditioning are 14 to 16 SEER. All gas pack furnaces are 81% AFUE. Still, the higher the SEER rating, the higher the cost.
- Unit Size – Air conditioners range from 24,000 BTU (2 tons) to 60,000 BTU (5 tons). Furnaces range from about 40,000 BTU to 130,000 BTU. There are furnace options for each ton of AC. For example, if you need a 3-ton air conditioner, you can select a 80,000 or 100,000 BTU furnace based on your home’s heating needs.
- Performance Features – The most affordable units have single-stage heating and cooling and a fixed-speed or multispeed blower motor. Price rises with two-stage performance and variable-speed blowers. Most upgraded features are on more efficient units.
- Brand Rating – Trane/American Standard, Lennox and Carrier are considered premium brands and cost the most. Goodman/Amana are budget brands and cost the least. The rest are priced in the middle. The most expensive gas packs can cost 50% more than the most affordable for comparable efficiency and performance.
- Dual Fuel Models – Some gas packaged units are built with a heat pump instead of an air conditioner. They heat with the heat pump when outside temperatures are above freezing and with the furnace when below freezing. Dual fuel, or hybrid heat as some brands call it, increases unit cost by $300-$450.
- Warranty – The length of warranties ranges from 5 years on parts to 12 years. Better warranties come with costlier products. ICP brands like Heil and Day & Night and Nortek brands like Maytag and Broan enhance their warranties with the promise to replace the entire package unit, not just the part, if the compressor or heat exchanger fails during the warranty period.
- Removal and Disposal of the Old Unit – The charge can range from $0 to more than $300.
- Demand at Time of Replacement – If you replace a gas pack during the peak heating or air conditioning season, estimates will likely be higher than during times contractors are less busy. If you choose to pre-emptively replace an aging gas/electric package unit before it fails in bad weather, you’re likely to save $400 to $600.
- Cost of Living – Like all consumer goods, HVAC prices rise or fall with the cost of living. If you live in a large metro area of the Northeast, Northwest, AK or HI, costs will be higher than if you live in the Midwest, South or rural areas.
Gas Pack and Supplies Cost
Retail Gas Package Unit Cost Range
(Gas Package Unit Only)
Total cost with installation and extras are listed in the top table. This section breaks down equipment costs to show how efficiency and performance affect cost.
- $2,200 – $5,100 | 14 SEER Gas Packaged Unit
- $2,750 – $5,400 | 15 SEER Gas Packaged Unit
- $3,100 – $5,675 | 16 SEER Gas Packaged Unit
Cost of Installation Supplies
In a direct replacement, it is possible that some of the old supplies are usable. However, most installations require at least some of this material. Discuss the details with your contractor.
The table at the top gives total costs for the furnace, supplies and labor. This section and the next gives itemized costs you might be interested in having.
- $75 – $300 | Sheet metal for transition / plenum to return and supply air duct.
- $40 – $760 | New Thermostat.
- $200 – $400 | Package unit pad for ground installation
- $500-$850 | Package unit rack and sheet metal for sloped roof installation.
- $65 – $115 | Electrical wire, and/or new breaker switch for connecting to power.
- $35 – $100 | Miscellaneous screws, fasteners, mastic, tape etc.
- $1,250 – $4,000+| New ductwork (if needed)
- $1,000 – $2,750 | Zoning controls (optional)
Permits, Inspection, and Unit Installation Costs
You’ll need a mechanical permit for the installation of a gas pack. If wiring is installed, an electrical permit might be needed too. Permits include inspections to ensure the work is done safely and according to local code.
- $50 – $200 | Packaged gas furnace installation permit with inspection
Installation Labor Factors
The labor cost to install a gas packaged unit starts at about $1,250 for ground installation and can cost more than $3,000 for rooftop installation.
The labor cost for your project will be determined by these factors:
- Ground or Rooftop – When installed on a roof, a crane or boom must be used. If the contractor has to rent the equipment, cost will be significantly higher than if the contractor owns a boom.
- Installation of Supplies – The more “extras” are needed, such as sheet metal modifications or installing a rack on the roof, the more labor is needed. That makes the cost higher.
- Size of the Unit – If a larger crew is required for a 4-ton or 5-ton unit, then the labor cost will increase.
- Removal and Disposal of Old Unit – It takes a couple hours to disconnect and remove an old unit. This can add several hundred dollars to the price. Disposal alone costs up to $75.
Package Unit Installation Time
- 1-3 days | Install new ductwork, if needed
- Up to 1 day | Prepare roof or ground for installation on a pad or rack
- Up to half day | Remove old HVAC equipment
- About 1 day | Install, connect and tune a new package unit
Gas packaged units are a key part of your home heating and cooling system. Below, you’ll find several other home HVAC related projects and their costs.
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DIY or Hire a Pro
Gas packaged units are easier to install than split systems, but there are a few considerations before doing it yourself.
First, DIY installation voids your warranty. Manufacturers don’t want the risk of covering problems on equipment installed by non-professionals. For that reason alone, we recommend pro installation. Since the entire job is a major investment – one of the 10 most expensive home repairs – it’s important to do it properly.
Secondly, rooftop installations are inherently dangerous. You also accept the risk should the unit, your home or property be damaged. We recommend pro installation of rooftop HVAC equipment.
While we don’t recommend this, if you’re handy and the unit is on the ground, you might be able to remove the old unit and set the new unit. Then, hire an HVAC pro to hook up the gas pack, tune and test it and sign off on the installation. Most busy contractors want the whole job or nothing, but if you have a relationship with an HVAC pro or it’s the slow season, you might find one willing to work with you.
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