No, the furnace doesn't run all the time to keep up, when it's really cold out it kicks on a lot but I guess that's what it's suppsed to do. Yes one of the contractors mentioned duct size with respect to cracked heat exchangers. However I've had three contractors give me quotes on replacing the furnace and none have suggested changing the duct work. They just want to pull out the old one and slide in the new one and charge a thousand dollars labor to do it. Bob