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Cost may vary depends on the house size, accessibility, the amount of work involved in duct reworking, disconnecting/connecting gas electricity. Normally, it's better to replace AC/coil/Furnace all together, since a new furnace may not be compatible with old indoor blower /evaporator coil.
Air return duct and filter grille size is dictated by the size of the unit (CFM) not the size of the house.
a 4 ton unit
Use the square footage of your house, and the size of your roof should be about the same. Be carefull not to include the yard in the footage or anything that is not covered by the roof, then divide the number by the number of stories your house is.
How tall a stairway should be depends on how tall your house is. They can vary in size because they depend on how tall your house is. Stair railing on a stairway should not be more than 34 inches and no less than 30 inches.