My HVAC System in Southern Orange County is Flat (Low on Freon) — Now What?

If your HVAC system has been diagnosed as flat (completely out of refrigerant) or low on refrigerant, you’re probably wondering what to do next. If you’re looking for answers or services to prompts such as: “I need refrigerant/freon recharging” or “Do I need to add freon to my HVAC system?” or even “How frequently do I need refrigerant?”, read on! Many homeowners worry these topics insinuate they’ll have to replace their entire system, but that’s not always the case.

Before making any decisions, it’s important to understand what’s going on with your system, the type of refrigerant it uses, and what repair options are available.

Understanding Refrigerant Changes

Over the last several years, there has been a major shift in the HVAC industry away from older refrigerants like R-22 and R-410A:

• R-22 (Freon):

  • Phased out due to environmental concerns.

  • Production and import have been banned since 2020.

  • Only recycled or reclaimed R-22 is available, making it expensive and hard to find.

• R-410A:

  • The current standard for most systems installed over the past 10-15 years.

  • Being phased out starting in 2025 and replaced with new, lower-GWP refrigerants like R-32 and R-454B.

  • While still available, costs are steadily increasing as manufacturing slows down.

Note: You can no longer purchase a new system designed for R-22, and as of 2025, R-410A systems will also start to be phased out in favor of newer, more eco-friendly refrigerants.

Do You Need a Whole New HVAC System?

The short answer: No — not necessarily!

A refrigerant leak doesn’t automatically mean you need to replace your entire heating and cooling system. In many cases, the problem can be fixed by finding and repairing the leak, then recharging the system.

Here’s how to determine what’s next:

1. Finding the Leak

Most HVAC systems leak refrigerant because of wear and tear, vibrations, or corrosion over time.
The most common leak locations include:

• Outdoor Condenser Unit (Most Common):

  • Located outside, so it’s exposed to sun, weather, plants, and other elements.

  • Damage often occurs from corrosion, physical wear, or vibration.

• Indoor Evaporator Coil:

  • Located inside your air handler or furnace.

  • Leaks here are usually due to corrosion or manufacturing defects.

• Copper Refrigerant Lines or Fittings:

  • These run between the indoor and outdoor units and can develop leaks due to rubbing or accidental damage.

2. Repair vs. Replacement Options

Once the leak location is identified, here’s what you can expect:

• If the leak is in the refrigerant lines or fittings:

  • Best-case scenario!

  • These can often be repaired without replacing major components.

  • After repair, a vacuum is pulled on the system to verify it’s sealed before recharging with refrigerant.

• If the leak is in the evaporator or condenser coil:

  • The leaking coil will need to be replaced.

  • Good news: You don’t necessarily have to replace the entire system — just the damaged component.

Example: If the evaporator coil inside is leaking, only that part can be swapped out, saving you thousands compared to a full system replacement.

A Real-Life Example From One of Our Clients

We recently helped a homeowner in Southern Orange County whose AC had completely stopped cooling.

Our diagnostic process revealed the system was completely flat — no refrigerant at all. After carefully inspecting the unit, we discovered the cause:
An electrical wire had been rubbing against one of the condenser’s copper lines. Over time, the wire’s insulation wore away, and when the live wire touched the copper, it burned a tiny hole right through it. The refrigerant quickly escaped through this hole.

Solution:

• The damaged section of the copper line was repaired.

• A vacuum test was performed to ensure there were no other leaks.

• The system was recharged with refrigerant.

The result? The homeowner didn’t need to replace the condenser, evaporator coil, or full system — just a targeted repair.

Why You Shouldn’t Panic About a Flat System

At Fortt Mechanical Inc., we’ve helped countless Orange County homeowners save money by repairing refrigerant leaks instead of replacing their entire HVAC system. Even when a leak can’t be fixed directly, there are often middle-ground solutions, like replacing only the faulty half of the system.

Benefits of repairing instead of replacing:

• Lower cost compared to full replacement.

• Extends the life of your existing equipment.

• Allows you to plan and budget for a future upgrade rather than rushing into it.

When a Full Replacement Might Be Worth Considering

While repairs are often possible, there are situations where replacement makes sense:

• Your system is over 15 years old and inefficient.

• The cost of repair is more than 40% of a new system.

• Your unit uses R-22 refrigerant, which is extremely costly and hard to source.

• You want to upgrade to a modern, energy-efficient system with newer refrigerants.

We always provide clear, honest advice to help you decide what’s best for your home and budget.

We have had incredible success locating and repairing refrigerant leaks. Even when the leak can’t be located, we can frequently save our clients significant amounts of money by only replacing half the system. If your HVAC system in Orange County is compromised and is leaking or has lost all its refrigerant, we have the tools and experience to bring you the most affordable solutions.