First has made the same products for many years. You can probably buy a new pan from them. If they won't sell to you, make sure they have a pan available, then find a distributor willing to sell to you. Many local suppliers have bought from first over the years. First may have discontinued the product, but the replacement product may be the same size. You need to ask them if this happens. Pans can be made by a local sheetmetal shop. In the past they would have cost less than $50. I have not had the need for a replacement pan in more than 10 years, so prices are not current. Depending on where you live in Dallas, the prices for service can vary. Park Cities pay more for service. Frisco pays more. The company makes indoor coils and air handlers for York. It is a large company that has proved helpfull to me in the past. Before you call them know the model of the coil if possible, and the dimmensions of the pan. I saw a repair kit at a local supply store. I have used epoxy on evaporative coolers in the past, but never on an AC pan. The repairs I made were on the roof. Leaks would only reduce efficiency of the cooler. I recently saw a repair made on a tub with exoxy. It looks strong 2 months later. I would not normally consider this type of repair, but the customer was willing. I have gone back several times to fix problems at that house.

The connection between the evaporator & the AH should be sealed, however, a lot of them will have a little air leakage. More important is to test the ESP static pressure before the blower & between the AH & the E-Coil. Also, the CFM to each room should be checked & added for the total CFM. - udarrell Here is a link that might be useful: Air Side of Air Conditioning

I am not optomistic about utilizing new coils at latter date that are installed now. At best it limits your options for replacement heat pumps. I lean toward "wait and see" because you hadn't noticed any change in performance.

Yes I absolutely agree with you nothing is perfect, with any HVAC system, or with any house hold appliance as a matter of fact. I have had 3 installations in 10 years, one was so bad and wouldn't pass code that I forced the installer to remove and reimburse me, that's what brought me to American Standard, the first unit was TAM 7 and I had no problems, sold that house and moved into my current house so when it came time I used the same installer and upgraded to the TAM 9. Little did I know that quite a bit of change happened in the company and the product, goes to show you that you always need to do your homework regardless as things change over time. If I had to do it again I would most likely go with Carrier but I would need to do my homework. The coils are bad, there is galvanic corrosion everywhere due to the use of dissimilar metals, I know this for a fact as I worked in the offshore oil and gas businesses for over 20 years designing and manufacturing the electrical, optical and hydraulic connection systems and have seen my fair share just as I sure you have seen yours. I can only imagine what you have seen thru the years and I'm sure many left you scratching your head and saying what the... I know I see it all the time and it baffles me too...