Here are some signs that indicate a cracked furnace heat exchanger:
1. Soot or rust on the furnace or around the flue pipes.
2. Unexplained headaches or flu like symptoms.
3. Water condensation near the furnace.
4. Higher than normal gas or electric bills without explanation.
5. A yellow or orange flame instead of a blue flame inside the furnace.
6. Frequent cycling on and off of the furnace.
If you suspect a cracked heat exchanger, it's important to have your furnace inspected by a professional furnace repair technician right away.