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The size of the duct is 8 inches or so - we have 17 heating vents and 7
air intakes - though some are joined in the system. Should I
add vents or intakes or make the plenum bigger - have people...

Sorry, the plenum is 24x24x48 inches

The plenum is 24 x 24 inches. I am not sure of the size of the old
furnace - never really looked - but is was really quiet - it seems the
amount of air being pushed is the same and the flow of air...

York gave us a new inductor motor and we replaced it - the contractor (brother
in law) did this. I also redid the piping for the exhaust and intake - my
contractor put in 10 90 degree's elbows -...

I appreciate all that you are doing and saying....I have the service manual and training manual for service people - the dip switches are: Continuous fan, A/R, Delay, Cooling Speed, and Adjust.
...

Thanks guys...the dip switches are for the Continuously ON setting. There is no dip switch for the blower speed (this is the first thing I though, but no control for this).

It is noisy though out...

It's a PC9*

We put on about 5 90 elbows on the exaust (max according to specs). I did hear that a common problem with these is the gas pressure and pressure may be too high eventhough specs say it is fine.

I...

The unit is a Modulating furnace and I can hear the sound as soon as the
unit turns on (obviously louder as it hits it's max.). As the unit ramps up the sound increases.

The guy who checked the...

Thanks jrbenny,
We checked the jumpers and there is no jumper for the Blower speed. The duct work is original for the house. The furnace is 80K btu and the
house is about 2700 sq ft.

Thanks ampulman. I looked and looked, but I found no others who have the same problem with their furnace.

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We have a York 96 Affinity furnace and was installed last month. While running the unit creates a great deal of noise. It sounds like a jet engine. I called the installer back out and he checked...