Several years ago one of the head studs broke as well.  In this case we were
simply driving along and the van just died.  Upon closer inspection i found
that one of the studs had broken off.  Oil mixed in coolant system and
coolant mixed in the engine block, a real mess.  After a tow back home i
removed the head and found the stud had sheared off flush with the top of
the head.  To make a long story short - head came off, tried to remove with
a variety of tools but no go.  Used a stud extractor and still would not
come out, in fact i broke the stud again leaving even less of the stud
exposed above the block.  Finally pulled one to the cylinders and
corresponding pistons and used a propane torch and heated the area on the
block where the stud threads in.  Some heat and the use of the stud
extractor worked after some tense moments.  A stud extractor mounts on your
rachet and wraps itself around the stud, as you work the ratchet the
extractor will not only screw out the stud but will grip it even tighter the
more force you apply.  DON"T use too much heat or you might risk damaging
the engine case.
This was a major PITA.  Good luck.
Claudio Cella
1987  Vanagon  GL  7 pass
90  Jetta  TD
----- Original Message -----
From: "Jeffrey Schwaia" <jeff@TSSGI.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Wednesday, February 26, 2003 5:07 PM
Subject: Re: Broke off stud torqueing head-what do I do?

> Loretta,
>
> Bad news time.  If one stud broke, you can be sure that at least some of
the
> others are corroded as well (common problem).  Additionally, they can be
> buggers to get out.  Take them all out for inspection and replace the any
> that look even the slightest bit corroded.
>
> Good Luck,
>
> Jeff
>
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@GERRY.VANAGON.COM]On Behalf
> Of Loretta Abbott-Kennon
> Sent: Wednesday, February 26, 2003 12:07 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Broke off stud torqueing head-what do I do?
>
>
> Hello List...  I'm back after being away for a few months.  A lot has
> happened, my grey Syncro that I bought in Montana last Summer was smashed
> while parked in front of my house.  So now I have a syncro partsmobile in
my
> back yard along with the westy... anyone need any parts?
> Back to my reason for posting; I am trying to replace the head gaskets on
my
> 90 and have the engine out.  Unfortunately I broke one of the long studs
> that hold the head on while trying to do the final torque. It is broken
> leaving quite a bit of the shaft exposed, basically only the end threaded
> portion was broken off.  My question is what do I need to do now?  I
> searched the archives and only found info on exhaust studs.  Will this
back
> out with a tool?
> Any suggestions will be appreciated.
> It's good to be back!
>
> --
> Loretta Abbott-Kennon
> "Another veteran against war with Iraq"
> www.veteransforpeace.org
> 1987 Syncro GL
> 1990 GL Automatic
> 1982 Westy L
> 86 Syncro GL & 82 Westy L Partsmobiles
>
>
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