Mark Callahan’s Deep Dive: Ducted Heating System Cost, Heat Pump Insta

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Introduction

Hey folks — Mark Callahan here, scratching out this blog from the crawlspace of yet another retrofit job. Over the years I’ve seen two things happen again and again: homeowners focus on the condenser or AC side (and maybe that’s your Goodman bundle) and neglect the heating side—or they upgrade equipment but neglect the ductwork or distribution system. If you’re looking to install the Goodman 3 Ton 14.5 SEER2 R‑32 bundle (smart move), you’re already halfway there on the cooling. But comfort is year‑round, and so is cost.

Today I want to talk about the heating side:

What a ducted heating system cost looks like (especially when paired with ducts + heating equipment)
What a furnace pump replacement cost is (yes — pump meaning blower/air‑handler/furnace combo)
What you should expect in the cost to install a heat pump and ducts (if you’re thinking of electric/heat pump heating instead)

Because if you skip these, your cooling side might shine — but your year‑round comfort and bills may suffer. So let’s get into it.

1. What the Goodman 3 Ton 14.5 SEER2 R‑32 Bundle Covers—and What It Doesn’t

Before we dive into heating cost, I want to clarify what you’re buying with the Goodman bundle. This unit handles your cooling (and potentially part of your heating if you have heat pump configuration, though often it’s just AC). The specs: 3‑ton (≈36,000 BTU/hr) capacity, 14.5 SEER2 efficiency rating, using R‑32 refrigerant. It’s matched condenser + indoor coil/handler. For many homes (~1,500‑1,800 sq ft depending on climate) this is strong.

But here’s what it doesn’t cover:

It doesn’t necessarily cover the heating equipment unless you choose a heat‑pump version or pair with a furnace.
It doesn’t automatically fix or address aging ductwork, leaking air delivery, undersized plenums, or poor insulation.
It doesn’t guarantee that your blower or distribution system is sized right for heating mode.

In other words: upgrading your cooling is great, but if your heating system (ducts + furnace/air‑handler + controls) is weak, you’ll still feel it when winter hits. That’s where understanding cost structure matters.

2. Understanding “Ducted Heating System Cost”

When I say “ducted heating system cost”, I mean the full cost of a heating system that uses ducts (rather than baseboards or radiant) — including equipment, installation labor, ductwork distribution, controls, and any modifications.

What cost‑guides show

The site HVAC.com shows that installing an HVAC system with ductwork (cooling or heating) typically runs $9,500 to $13,500 for a 3‑ton system when you already have some infrastructure. They estimate new ductwork separately between $2,000‑$3,000 per ton. (HVAC.com)
Another cost guide for heat pumps & whole‑system replacements shows that entire system costs (heat pump + ducts + install) for 1,500‑2,500 sq ft homes often fall in the $17,000‑$23,000 range. (Rewiring America Homes)
Additional ductwork alone (installation or replacement) can cost $1,400‑$5,600 or more depending on condition. (Call Waldrop)

What impacts the ducted heating system cost

Size of home / heating load: Larger homes need higher capacity equipment, more duct length, bigger plenums.
Condition of existing ducts: If ducts are leaky, undersized, poorly insulated or located in unconditioned spaces, you’ll pay for sealing, insulation, possible replacement.
Installation location & access: Attic, crawlspace, tight spaces add labor time.
Efficiency & equipment quality: Higher efficiency blower motors, variable speed, premium controls cost more upfront but smaller operating cost.
Fuel type / system type: Electric, gas furnace, heat pump—each has different cost profiles.
Controls & zoning: If you add zone dampers, smart thermostat, bypass systems, that adds cost.
Ductwork modifications: If you’re changing system capacity (e.g., choosing bigger cooling/heating unit like your 3‑ton Goodman) you may need duct re‑distribution or enlarging supply/return runs.

Rule‑of‑thumb for homeowners

If you’re going to budget for a ducted heating system cost in a typical mid‑sized home that’s also getting new cooling, a rough expectation might be $8,000‑$15,000 for heating side (ducted) assuming moderate ductwork and moderate capacity upgrade. If major duct replacement is needed or large home size, the cost can easily go beyond $15,000.

3. “Furnace Pump Replacement Cost” – What It Means & What to Expect

When I say “furnace pump replacement cost,” I’m referring to replacing the blower/air‑handler/furnace portion of the system (the “pump” metaphor meaning the moving air portion)—especially in a ducted system. This might not always mean a full furnace replacement (especially if you keep existing ducts and outdoor unit), but often means a major component swap.

Why this cost matters

If your cooling side is new (Goodman bundle) but your blower/furnace/air handler is old, mismatched or inefficient, you’re losing performance regardless of how good your condenser is.
Upgrading the “pump” portion often means new blower motor, updated air handler, possibly new furnace cabinet (if gas), updated controls.
If ducts are changed concurrently, the pump replacement cost merges into broader ducted heating system cost.

Typical costs

While many cost guides talk broadly about furnace replacement or heat pump replacement, one useful benchmark is that replacing the full air‑source heat pump system (which includes outdoor + indoor + ducts) ranges from ~$8,930 to ~$14,160 for many homes. (Heat Pump Price Guides)
If you isolate just the indoor “pump” side (air handler/blower/furnace) and you’re re‑using existing ducts and outdoor equipment, you might expect significantly less — perhaps in the $2,000‑$5,000 range depending on size and region — but if upgrades are needed the cost can jump.

What factors drive up pump replacement cost

Old or inefficient blower motor (you upgrade to variable‑speed, ECM motor)
Air handler location (attic, narrow chase, difficult access)
Matching to new condenser (if cooling side changed) or new outdoor unit
Wiring, controls, thermostat upgrades
Duct leakage/repair required at same time — many contractors bunch this into pump cost but it inflates the number

Practical tip

If your quote says “furnace pump replacement cost $3,000” but you’re also getting new ductwork or new outdoor condenser, ask for itemization. Make sure you’re clear on what’s included. The blower/air handler swap alone should be a lower baseline; if the cost is high, confirm what extras are driving it.

4. Cost to Install Heat Pump and Ducts – A Full Scope Look

This is where many homeowners are surprised: the cost to install heat pump and ducts can be significantly more than just replacing equipment. Especially when you’re saying goodbye to old fuel‑based systems or adding/renewing ductwork.

What do cost‑guides say?

According to EnergySage, average cost to install a heat pump in 2025 is around $16,500 after incentives for a full home system, ranging higher based on home size and complexity. (EnergySage)
Another guide lists that a full heat pump system for 1,500‑2,500 sq ft homes ranges $17,000‑$23,000 (median ~$19,500) when including ducts/air handler/outdoor unit. (Rewiring America Homes)
HVAC.com suggests that installing new ductwork typically costs between $2,000‑$3,000 per ton of HVAC capacity. For a 3‑ton system that could be $6,000‑$9,000 in ductwork alone. (HVAC.com)

Putting it together: a sample scenario

Let’s say you have a 2,000 sq ft home. You’re upgrading your cooling (Goodman bundle) and you decide you’ll also install a heat pump and upgrade ducts. Here’s how you might budget:

Outdoor heat pump unit + indoor air handler: $8,000‑$12,000 (depending on tonnage & brand)
Ductwork upgrades (leak sealing, new runs, insulation): $4,000‑$8,000 depending on condition
Labor, electrical upgrades, thermostat/controls: $1,000‑$3,000
Contingency for surprises (attic access, old insulation removal): $500‑$2,000
Total cost: $13,500 to $25,000 depending on scope — which aligns with cost guides showing $17k‑$23k for many homes.

Why the cost can get high

If your ducts are in severe disrepair or located in hot attic/cold crawl space
If you’re converting from fuel (gas/propane) to electric heat pump (which may require panel upgrade, refrigerant lineset)
If you’re installing multiple zones or adding new rooms
If install access is difficult (roof, attic, crawlspace)
If you select high‑end equipment (variable‑speed heat pump, smart controls, premium air handler)

Connection with your Goodman cooling upgrade

Since you’re installing or planning to install the Goodman 3 Ton bundle, you’re already doing major cooling work. It makes sense to combine your ductwork upgrade, blower/air handler pump upgrade, and heating system upgrade (heat pump + ducts) into one project. You save on mobilization, labor coordination, and get better system integration.

5. My Field‑Technician Checklist: What You Must Ask & Inspect Before You Sign

When you’re evaluating quotes and budgeting, here are the on‑site things I always check and recommend you ask.

For Ducted Heating System Cost

Are the ducts sealed and insulated? Any duct leakage test done?
Are supply and return ducts sized appropriately for both cooling and heating load?
Location of ducts: attic, crawlspace, conditioned space — what difference does that make in installation cost and efficiency?
Are there shared ducts or crossover between floors? Will that affect performance?
Do you need to enlarge plenums, add balancing dampers, adjust airflow for the new system?
Include cost of duct modifications in your quote itemization.

For Furnace Pump Replacement Cost

What is the specification of the blower/air handler being installed? (e.g., variable speed, ECM motor)
Is the equipment matched to the condenser/heat pump or is it generic?
Access: Is the unit in attic, crawlspace, mechanical room? Any special rigging required?
Wiring and controls: Are thermostat/zone controls upgraded? Are there extra sensors or wiring runs?
Is the quote broken down—equipment vs labor vs materials? Compare to your pump replacement budget.

For Cost to Install Heat Pump & Ducts

Is the size of the heat pump matched to the load (Manual J)? Over‑sizing is a common mistake.
Are refrigerant lineset length, electrical service size, disconnects, and permits included?
What is the condition of current ductwork and is it adequate for heat pump application (which may require different airflow or duct sizing than traditional furnace)?
If you’re converting from a fuel furnace to heat pump, what is the cost of removing old equipment, capping fuel lines, and reconciling codes?
Are rebates or tax credits applied or factored in?
Are estimated operating cost savings shown, or at least discussed, so you evaluate value, not just upfront cost?
When will the install be done? Off‑peak season often has lower labor cost.

6. Realistic Example: How This Works In a Home Setting

Let’s walk through a realistic scenario using your cooling upgrade as the anchor.

Scenario

You have a 1,800 sq ft home built in the 1990s. You’ve decided to upgrade your cooling with the Goodman 3 Ton 14.5 SEER2 R‑32 bundle. Your existing heating system is a 15‑year‑old electric furnace/air handler, and your ducts are in the attic and have experienced some leaks and insulation issues.

Your upgrade plan

Cooling upgrade: Install Goodman bundle.
Ductwork review: Seal attic ducts, add insulation, enlarge a few runs.
Heating upgrade: Either replace electric furnace/air handler or switch to a heat pump tied into the ducts.
Air handler/blower (pump) replacement: Install new variable speed air handler to match cooling/heating capacity.

Estimated Cost Breakdown

Goodman cooling bundle (installed): ~$6,000–$8,000 (assuming moderate labor)
Ductwork modifications (seal, insulation, upgrade): ~$2,000–$4,000
Air handler/blower replacement (“pump”): ~$3,000–$5,000
Heating system upgrade (assuming heat pump + ducts): ~$12,000–$18,000
Total investment: ~$23,000–$35,000

With that investment you get: improved cooling, modern heating system (heat pump or upgraded furnace), better ductwork, efficient blower, year‑round comfort, lower utility bills, less noise, better indoor air distribution.

Why this integrated approach matters

If you only upgraded cooling and left ducts/heating: your summer comfort improves but winter performance lags, bills stay high.
If you upgraded heating but left ducts poor: your system works harder, comfort suffers, efficiency is compromised.
By doing all together you maximize the return and reduce redundancies (one mobilization, coordinated install, less mismatch).

7. Why You’re Making the Right Decision — But Don’t Under‑Budget

Upgrading to the Goodman 3 Ton bundle is a smart move. But as your technician friend, I’m telling you: don’t look only at the condenser price. Consider the entire system cost. Because comfort, efficiency and long‑term value come from the complete distribution system.

If you under‑budget on ducts or the “pump” (blower/air handler) or the heating side (heat pump/furnace) you’ll still feel the deficiency. I’ve seen homeowners spend $7,000–$8,000 on a condenser and then balk at spending $4,000 more on ducts — they regret it.

The numbers from cost guides show why: heat pump + duct install often lands in the $17,000+ range. Ductwork replacement is $2,000–$3,000 per ton. Your ducted heating system cost isn’t trivial. And furnace pump replacement cost may be $3,000–$5,000 or more depending on access and upgrades.

So my advice: budget realistically, get multiple quotes with detailed breakdowns, integrate cooling and heating in one project if you can, and make sure your ductwork is up to par before you pay big for equipment.

8. Final Thoughts — Your Comfort Is A System, Not Just A Unit

Here’s what I want you to take away: The good folks at Goodman built you a strong cooling bundle (3 Ton, 14.5 SEER2, R‑32). But the home comfort equation doesn’t end there. Your air handler (pump), your ducts, your heating system—they all matter. The ducted heating system cost, the furnace pump replacement cost, and the cost to install heat pump and ducts are all real and significant. When you plan for them you avoid surprise cost, you install with confidence, and you sleep comfortably year‑round.

If I were standing in your attic next week, I’d say: “Great job on picking the Goodman bundle—now let’s inspect those ducts, size the blower, evaluate the heating side, and get the quotes in writing.” Because the install matters as much as the equipment. You’re doing the right thing—just make sure you budget accordingly, work with a good installer, and treat it as a full‑system upgrade, not just a “cooler box.”

Stay comfortable, stay informed—and let’s make your HVAC investment pay off for years.
— Mark Callahan