the good new is the green film is pobubly a lovely mixture of condensation mold and sediment ( like whats on top of a swamp) the drain should be cleaned and cleared. the bad new's is tonnage needs to be matched for eff. system life , propper operation, and warrantee. to start over might seem stupid but there is no easy fix to correct the mis match . Question why was the ductwork replaced and not the airhandler they basicly had the thing out and put it back. maybe start planing for that addition to justify keeping the 4 ton