Not only do I have an old furnace (circa 1976) in my house, I also have a large double unit (8 burners, circa 1981) at my office (for the second floor) and a smaller (but newer?) unit for the first floor (electronic ignition). That newer furnace (Whisper heat?) was a pain in the ass because the electronic ignition started to act up last winter and I took the electronic control module apart and resoldered the cold joint that developed at the ignition coil.
In the combined 10 years I've owned and operated these 3 furnaces, I've never called for a tech to service them, but the only one that had problems was the one with electronic ignition.
I've never had a problem with thermocouples. Yes, the heat exchangers are rusty, but I vacuum them out along with the burners every few years.
Crappy belts? Are you saying that belts used in 90+ furnaces are somehow different? In my experience, belts last a long time, even when I run the fan almost continuously for the 3 peak summer months.
If I were installing these furnaces back when they were new, I would have fabricated an exhaust gas and combustion intake heat exchanger to improve the efficiency of the units. That could have been done with all those units installed 20, 30 years ago to improve efficiency if they wanted to do that.
The idea of electronic ignition does not thrill me. Too much technology (and too expensive) given the savings.
The idea of a closed (sealed) combustion intake side (with scavaging heat from the exhaust side) does appeal to me - but that is basically "plumbing" and could have been done years ago with add-ons outside the furnace itself.
Something else I'd do is create a ducted, gated path around my AC evap coil so in the winter the air can flow around the coils instead of being forced through them.
Beyond a more efficient heat exchanger (which I presume they are today vs 20 or 30 years ago) I would think they'd be making them out of stainless steel by now (are they?). I would also think they would have variable gas valves (variable BTU output, instead of full-on or full-off) or staged valves. Do they have this today?
What about electronically commutated motors? How many furnaces have those today? I would replace my motors with those if they were available - at a reasonable price.
But you know what would really motivate me to replace my furnaces today?
Give me a furnace where the motor also runs on natural gas so I still have heat if there's a power failure.
I'd also like to see someone come out with a heat exchanger that has water sprayed onto it as a way to humidify the air (and take even more heat away from the exchanger and put it in the house). Does anyone do that?