Can you snap a pic of it with the face plate off so we can see how it's wired up right now. Also what is your system? Oil with A/C, Gas with A/C etc etc.....

A new washable one or like the Pleated Style filters? If the return isn't pulling air through enough it could let the unit heat up more than normal which would cause the limit to constantly trip. Sounds like it since you say it runs fine without a filter on there. I was using the M1MB gas furnace be...

Are you using the factory washable filter or are you using a different kind?

I usually throw a 3/4" Sharkbite Female Adapter on each Hot/Cold, stub up maybe a foot or so with PEX and then a 3/4" Sharkbite Ballvalve on each Hot/Cold and then run the PEX to where it goes or adapt to the existing.

Isn't there something that says that you should use metal pipe for the first 12" or something out of the water heater? Something about the PVC getting too hot when you come right out of the water heater like that? As long as it is CPVC & not regular PVC. CPVC is rated for the high temps of...

Yeah, now that makes sense now. The system would be pretty much sealed. So as long as the supply damper in the bottom of the indoor unit wasn't leaking you shouldn't be getting draft out of there. Unless the flex or outdoor section is letting air pass in through it which I could see for a older unit.

Necessary, no. Is it a good idea to do so, yes.

http://www.zipsystem.com/

Thats the way to go.

Yes, after the fan assembly is removed you should be able to see an outlet for the exhaust and there should be a plastic damper on it. Typically the fan assembly should be able to pop out and unplug the power for it.

I'm wondering if what your seeing is the plastic damper usually on the 3" outlet. So when it runs if you hold a piece of toilet paper up to it, it does not pull? Snap a picture of the fan inside if you can.

Yeah, there should be a damper in there. You can fab your own or do what 1987Commodore has done to his return. If it's your supply also then I would see what you can fab to fit. Usually they come off the package unit in Flex Duct something like 14" maybe.

Sounds like you have a typical "Package System" which is outside and has the blower/coils all in a big metal box looking thing. There should be Dampers already installed that will prevent hot air during heat use from going out the return duct and being wasted. And there should be another o...

what type of heat is your home? it might be worth it to use that money from the log set on a portable generator to power a few things in your home. When Sandy come through we were without power for almost 5 days here. I have 7,500 watt portable generator and my heat, stove & water heater are all...

Between my friends coming over on fight nights we probably put about 1,200+ lbs on the living room. As long as you catch some structure with that I'd imagine you should be just fine.

What's there, paneling? At least take down spots where you can gain access to plumbing fixtures like behind the shower to see and makesure nothing leaking.