The warm conditioned air is condensing on the cold concrete ceiling. But you also say this space allows access to plumbing in a bedroom. Is the entire ceiling concrete? At the least, you should be sealing this crawlspace from ground moisture. See the Building Science Corp. link below. Here is a link that might be useful: Crawlspace Design

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.

AC101 no doubt at all. The Am Std Allegiance 15. what stat was quoted? 3696839 Active Systems ALLEGIANCE 15 AMERICAN STANDARD, INC. 4A7A5030A1 4TEE3C04A1 31600 13.00 16.00 1419454 Active Systems ALLEGIANCE 15 AMERICAN STANDARD, INC. 4A7A5030A1 4TEE3F39A1 32000 13.40 16.00 either is fine but correct stat is important. both qualify for tax credit. what do you do about heat? post back. IMO

Hello Jackfre: Thank you for the rapid response. I will follow your advice on "DOE duct leakage". I assume the pressure test is after the new install, as old ducting is being removed. The house is 1 story but about 2200 SQ ft, with 1 large high ceiling room. I will also investigate a mini-split heat pump, though I know little about that just now. I have also found contractors guessing on tonnage,yet to find one that will show a Manual J calc. Think cutting this corner is a hint that other corners will be cut also. Thanks again for your response,it helps.