The nut going soft while tightening is actually a sign the stud was
stretching. If the engine was once overheated, all the studs are
suspect. If there is any corrosion on them, they must be replaced. You
will need to remove the head, and at least lift the cylinder out slight
to replace the stud. They are fairly tight in the case so some
imagination will be needed to remove it. Any others that tightened
weirdly should also be replaced. It is also a good idea to replace the
nuts or at least chase the threads with a quality tap. Never fill the
nuts with oil or sealer. Only apply to the stud threads. Good Luck.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Leo Lee
Sent: Wednesday, March 09, 2005 10:42 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Help! Cylinder head stud broken

I am about to finish the cylinder head job, everything went well, until
troqueing the head nuts to the last step to 36 ft lb. The number 4 nut
on the lower middle was a little soft and difficult to get to the right
tension. I adjusted all nuts to the right torque then went back to
tighten the last #4 nut. I do not know how but it did happen, the nut
and about an inch of the stud broke off from the head. I have spent
three weekend on the job, and do not know what to do next....
The first question is, can I block the stud tunnel with some sort of
liquid steel and run the engine with 7 nuts to secure the head?
The second question is how do I fix the broken stud? Do I have to take
to whole engine off?
Any suggestion will be greatly appreciated. Thanks

Leo, 1991 Westy Multivan, 110,000mls