Hi Larry
the stud is not Helicoiled into the case. The end of the stud that goes into
the case is larger than the body of the stud and is the same but is longer
than the nut end of the stud The case does not have an insert so it is
threaded into the block itself

So let me see if I have this right 1 top middle stud has broken twice and is
now flush with the case. If I have read this correctly the next problem is
that the drill bit needed to get straight onto the broken stud would need to
be 1 Ft long and very sharp. The cylinders and pistons are also going to get
in the way.

When I have this problem I am typicaly dissaembling the block for rebuilding
and after degreasing I send it to Jerrys Broken Drill and tap Santa Ana Ca
 Keep in mind this rot is not confind to1 stud and you might need to replace
all the studs
the bottom line is you cant just drill this out and the stud is very hard.
The location also is a huge problem
I would recomend another engine or engine block .

good luck
Bob

----- Original Message -----
From: "AAG - Larry Word" <word_aag@COMCAST.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Sunday, May 11, 2008 8:30 AM
Subject: 1985 Vanagon - engine case stud ? - Must have good answer - Calling
Boston Bob

I'm trying to avoid splitting my case/removing my engine in order to remove
an engine stud and R& R that stud which broke while traveling down the road.

The stud (drivers side stud, 2nd top from/toward driver) 1st broke about 1
inch from its end, 2nd brake while extracting at the engine's case - heli
coil into case?

? : Are the factory engine stud "Heli coils" (threads into alum. case that
hold stud into case) install/removed from the exterior side or interior side
of the case?

This may be important as we try our next extraction - I'm not willing to
remove engine and therefore it's "do or die" for this engine/perhaps my
trusted old vanagon.

Pls. advise if you have knowledge of this .....

Have a good day!

Larry
Ga.