Sounds like the metal gaskets are leaking exhaust into your cooling
jackets.....pushing out all of the antifreeze.   Shouldn't happen on a
decent rebuild at 25k mi.!  If so, it's back to the shop.  The sad part is
that the shop isn't going to take responsibility after 25000.

I would add, at the cost of sounding scolding *sorry*, that 80 mph is a lot
of work for a 91 hp engine to push a 5000 lb. brick.  I run 80 downhill at
times, but I know 70 mph can strain my poor 80 hp.  I know the flow of
traffic cooks along at  a good clip, but a vanagon isn't supposed to run
with the flow of the crowd, both literally and metaphorically.

Good luck, and I hope you find it's some easy fix!
brian cochran
84 westy
seattle

"If you're ever stuck in some thick undergrowth, in your underwear, don't
stop and start thinking of what other words have 'under' in them, because
that's probably the first sign of jungle madness." --Jack Handy

My fellow vanagon.com-er wrote:
Hello Vanagoners!

I need some help.  I believe that I have a leaky head gasket but I want to
get a confirmation about what I think is happening.  Here is what's
happening:

Around town and 1/2 hour drives the van runs great.  Heater works and it
never drips a drop of coolant.  The Van runs right at or slightly below the
red warning light.

Yesterday I drove almost 400 miles in one day.  (To much driving)  Traveling
at about 70 to 80 mph the entire time.  With two stops inbetween everything
seemed fine.  (Now that I recall at one stop there was a faint smell of
antifreeze but I couldn't find anything coming off my van.)  When I pulled
off the freeway right by my house, and slowed the van down, the light
started flashing and the needle pegged.  I pulled over and the expansion
tank was low on water.  The reserve tank was full and the water had all
dumped out somewere on my trip.

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