Introduction
Hey everyone, Mike Sanders here.
If you’re upgrading your home with a new 5-ton R-32 AC and gas furnace combo, congrats — that’s a big step toward a more comfortable, energy-efficient future. But I also know that HVAC installations can feel mysterious if you haven’t been through one before.
That’s where this article comes in.
Whether you’re working with an HVAC pro or doing your homework before you choose one, knowing what happens before, during, and after installation will help you make sure you get a quality job.
I’ll walk you through my personal checklist for a 5-ton R-32 AC and gas furnace installation. Let’s go step-by-step so you know what to expect.
Pre-Installation Steps: Getting Ready
Before the installers show up, there’s some important work that should happen — work that often separates a quality install from a rushed one.
✅ 1. Load Calculation and Equipment Selection
Your contractor should do a full Manual J load calculation before they recommend a system. This is the most accurate way to size your new 5-ton AC and furnace to match your home’s specific cooling and heating needs.
Why does that matter?
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Too small a unit and it will struggle to keep up.
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Too big and it will short-cycle — wasting energy and wearing out sooner.
💡 More info: Energy Vanguard’s guide to Manual J calculations explains what to look for in a proper sizing process.
✅ 2. Confirming Ductwork and Airflow
Next up: making sure your ductwork can actually support a 5-ton R-32 system. Ducts that are too small, leaky, or improperly sized will choke airflow and kill your new system’s efficiency.
Your installer should inspect existing ducts — looking for:
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Poor insulation
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Leaks or disconnected sections
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Damaged returns or registers
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Proper sizing for 2,000 CFM of airflow
And if they recommend duct sealing or modifications? Take that seriously. Well-sealed ducts can improve comfort and reduce utility bills by up to 20% — especially for high-capacity systems like a 5-ton AC and furnace combo.
💡 More info: The U.S. Energy Star program’s duct sealing guide is a great resource for understanding duct efficiency.
✅ 3. Checking Refrigerant Lines and Venting Requirements
With an R-32 refrigerant system, your installer will need to plan the refrigerant line set carefully. This is also a good time to check your furnace venting — especially if you’re upgrading to a high-efficiency gas furnace with an AFUE of 90% or more.
Venting types:
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PVC for direct-vent high-efficiency furnaces
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Existing chimney liner if using a non-condensing furnace
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Condensate drains for high-efficiency models
💡 More info: The AHRI refrigerant safety guidelines cover proper refrigerant handling and safety requirements.
Installation Day: What to Expect
When installation day rolls around, most pros will tackle these steps one by one. Be prepared for the job to take 6-10 hours — sometimes more if you need ductwork or electrical upgrades.
✅ 4. Removal of Old Equipment
Your team will:
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Shut off power and gas to existing HVAC equipment
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Recover the refrigerant properly
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Remove the old AC unit, furnace, and any disconnected duct or refrigerant lines
Your installer should also take care to prevent dust and debris from spreading around your home. Drop cloths and floor protection are a must!
✅ 5. Installing the Furnace
With the old equipment out of the way, the gas furnace is usually first to go in. The steps they’ll follow:
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Place and level the new furnace
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Connect gas lines — including shutoff valves and a drip leg to catch sediment
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Connect exhaust and intake pipes
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Run a dedicated condensate drain if you chose a high-efficiency model
Your furnace will also need proper electrical connections — usually a 120V line for most residential setups — and a thermostat wire to your chosen thermostat.
✅ 6. Installing the R-32 AC Outdoor Unit
Next up is your condenser. For a 5-ton system:
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The tech will set the unit on a level pad outside, making sure to leave proper clearance on all sides
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Run a properly sized refrigerant line set between the condenser and indoor coil
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Charge the system carefully with R-32 refrigerant to manufacturer specifications — R-32 is more efficient and less GWP than older refrigerants like R-410A
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Wire the outdoor unit into your electrical panel with an appropriate disconnect switch nearby
✅ 7. Installing the Evaporator Coil
Your evaporator coil will sit on top of or inside the furnace plenum. This is the indoor part of the AC system:
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Techs will seal the plenum properly
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Install a drain pan and drain line to remove moisture that the coil pulls out of the air
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Check refrigerant line insulation to prevent energy losses
✅ 8. Installing the Thermostat
If you’re upgrading to a new programmable or smart thermostat — this is the time.
Your tech will wire the thermostat and check its calibration. If you choose a WiFi thermostat like Nest or Ecobee, they’ll often help you set up the app too.
Start-Up and Commissioning
Once all the pieces are in place, your contractor will do a thorough startup and commissioning process. This is a big one — it’s your chance to catch any problems early.
✅ 9. Pressure Testing and Leak Check
Your tech will check refrigerant lines for leaks and proper pressure levels. This is critical for R-32 refrigerant systems — even small leaks can reduce efficiency.
✅ 10. Proper Airflow and Balance Testing
Your tech will verify that:
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The fan is delivering the correct airflow (CFM) for a 5-ton system
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Duct dampers and vents are properly balanced so each room gets the right amount of air
✅ 11. Safety Checks
Your furnace’s gas connections will be tested for leaks. They’ll also check safety controls like:
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Flame sensors
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Pressure switches
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Limit switches
And if your new furnace is high-efficiency? They’ll check the condensate drain and the exhaust vent too.
✅ 12. Final Performance Test
Finally, they’ll let the system run for a full cycle. That includes:
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Cooling mode — check temperature drop across the coil
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Heating mode — check furnace ignition and gas pressure
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Confirm that all safeties, sensors, and controls are operating properly
Your contractor should also show you:
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How to change your filter
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What routine maintenance looks like
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How to use the thermostat
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What to do if you hear odd noises or see error codes
Post-Installation Considerations
Your install crew will clean up the job site, dispose of your old equipment properly, and leave your home just as clean as they found it.
✅ 13. Registering Your Equipment for Warranty
Don’t forget to register your new AC and furnace with the manufacturer — most major brands require registration to activate extended warranties. Goodman and other top brands offer 10-year parts warranties and sometimes lifetime heat exchanger warranties when you register on time.
✅ 14. Scheduling Routine Service
Ask your installer about an annual maintenance plan.
Most warranties require yearly checkups to stay valid — and regular service will keep your 5-ton R-32 AC and furnace running efficiently for 15–20 years.
💡 More info: Check out ENERGY STAR’s maintenance checklist for tips on keeping your system in top shape.
Final Thoughts from Mike
That’s the full rundown of what to expect with a 5-ton R-32 AC and gas furnace installation. From pre-install planning and Manual J load calculations to proper refrigerant handling and safety checks, every step matters.
When you work with a pro who follows this kind of thorough process, you’ll enjoy a system that’s:
✅ Efficient
✅ Reliable
✅ Safe
✅ Backed by a strong warranty
And most importantly? Comfortable — year after year.
If you’re looking for top-rated 5-ton R-32 AC and gas furnace combos, check out the full collection at The Furnace Outlet. They have a great selection of proven models at competitive prices — so you can make your upgrade with confidence.
