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RE post #31:
Are the bends tight like a 90 degree elbow or do the sweep for the bend. The turns, regardless of sweep will increase static pressure. You mentioned it's a 24" flex. Looks like a central return system with only the one main return. If that 24" flex is crushed like in the pic, along with the extra turns and length, you likely don't have adequate airflow. If the supply duct is as crappy as the return, you could have bigger issues. Flex duct increases static pressure and the furnace might not be able to overcome the poor duct design.
If you look at your air conditioner size, you'll have a series of numbers and then see something like 024 (two ton) up to 060 (5 ton). The 24" should be sufficient for a 5 ton system but with the length and the kinks in the duct, even straightening it out might not help.
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Nick
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