I replaced all the ducts but the trunks in my 1969 home when I replaced the horizontal furnace under the house with a gas pack. I got advice from a friend who was an HVAC contractor. I was surprised to find the trunks and other ducts very clean. I replaced the individual runs with flex primarily for the insulation. I wrapped the trunks with insulation also.

Installation: Replacement is quite easy, especially when an old refrigerant line set can be used. If the set is worn, it’s much better to pay the extra $400-$600 to replace it rather than risking it leaking later. When your AC loses refrigerant, you lose your cool air and the compressor is at risk of failing. A new installation means installing a coil in your furnace or air handler, running the line set between it and the coil in the condensing unit and adding refrigerant, if needed. Most ACs come pre-charged for 20-30 feet of line. If the line set is longer, a small amount of refrigerant is added.
The number of years an HVAC system lasts depend on the type and brand of components that make up your system. The lifespan of an air conditioner averages between 15 and 20 years. The life expectancy of a tankless water heater is approximately 20 years, while a storage water heater is closer to 10-15 years. Ducts may need replacing within 10-15 years. Your equipment will have a longer life if you have regular tuneups and maintenance to keep everything in good working order. If you’re having repair problems and your HVAC system is over 10 years old, it’s a good time to consider the costs and benefits of repairing vs. replacing. Energystar.gov provides the following tips to help you decide whether to repair or replace:

Duct cleaning has never been shown to actually prevent health problems. Neither do studies conclusively demonstrate that particle (e.g., dust) levels in homes increase because of dirty air ducts. This is because much of the dirt in air ducts adheres to duct surfaces and does not necessarily enter the living space. It is important to keep in mind that dirty air ducts are only one of many possible sources of particles that are present in homes. Pollutants that enter the home both from outdoors and indoor activities such as cooking, cleaning, smoking, or just moving around can cause greater exposure to contaminants than dirty air ducts. Moreover, there is no evidence that a light amount of household dust or other particulate matter in air ducts poses any risk to your health.
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