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Today's Hours 8am - 11pm estI have a 2400 sq. ft home w/furnace in basement. What size for new unit?
It is strange that our sizing chart is recommending you a larger furnace. In your specific situation, I would recommend basing a decision on more than just a sizing chart. Our chart is more of a guide and does not completely take place of any true heat load calculations that a professional would do. Consulting an HVAC tech would be the next step I recommend taking as they will give you a better idea of what size furnace to get for your home.
Judging from the information you have provided regarding the furnace's age and BTUs, it sounds like your furnace is single stage and roughly 80% efficient at best. If this is the case, then you are getting 62,000-64,000 BTUs of heat into your airstream. If you wanted to upsize a little, the G96VTN1002120A would be a good choice. This model is two-stage and 96% efficient, which means that you will be getting 96,000 BTUs at a high-stage setting and 63,000 BTUs at a low-stage setting. The low-stage setting is comparable to what you are getting now, but you will also have the benefit of turning on a higher setting if you need the extra heat.
Before making the decision on a furnace, please make sure you have your home properly sized by an HVAC tech first. We will then be able to direct you to the correct furnace with greater accuracy.