Every homeowner eventually faces the repair vs. replace question on a major system. The wrong call costs thousands -- either you spend $600 on a repair that fails again in a year, or you replace something that had years of life left. Here's how to decide for every major system.
The 50% rule (and its limits)
The general guidance: if a repair costs more than 50% of replacement, replace. If the system is in the last third of its expected lifespan, the threshold drops to 30-40%. This rule works well for appliances and water heaters. For HVAC, roofing, and structural systems, other factors matter more.
HVAC systems
Repair if under 10 years old and the repair is a single component (capacitor, contactor, reversing valve). Replace if: over 12 years old AND requiring a major repair (compressor, heat exchanger), if R-22 refrigerant is needed (it's being phased out), or if efficiency is so low that the energy savings of a new unit pay back within 5-7 years.
Water heaters
Repair if: under 7 years old, single component failure (thermostat, heating element, anode rod), and repair cost is under $400. Replace if: over 10 years old, tank is leaking or rusty, or you've already repaired it once. Consider upgrading to a heat pump water heater -- federal tax credits cover 30% of cost.
Roofing
Repair if: damage is isolated (one slope, localized flashing failure, small area of missing shingles) and roof is under 15 years old. Replace if: over 20 years old, damage is across multiple areas, shingles are at end of life (widespread granule loss, curling), or you have multiple active leaks.
Appliances
Use this rule: Refrigerators and dishwashers under 8 years old are worth repairing if the repair is under $400. Washing machines over 8 years old with major repair needs (motor, transmission, control board) are almost never worth repairing. Ovens and dryers are generally worth repairing if under 10 years old.
Bottom line
The repair vs. replace decision comes down to age, repair cost as a percentage of replacement, and whether there's a pattern of failures. When in doubt, get a professional assessment before committing to either path.
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