Jim-

Don't even THINK about "going without" one of your head studs. Not unless
you are a glutton for punishment. You would never relax and enjoy your van
again, constantly pinching your sphincter while driving, having to carry
jacks and tools, wondering when your "little experiment" would fail... like
Damocles Sword.

I don't play in the water, but if they are built like the air, you don't
have to split the case. Follow the advice of the water-cooled brains in the
collective.

G. Matthew Bulley
Bulley-Hewlett
Corporate Communications Counselors
www.bulley-hewlett.com
Cary, NC USA
888.468.4880 tollfree

------------------------------------------------------------------------
----------------------
Get your FREE semi-private E-mail account, use your computer at work.

-----Original Message-----
From:   James Ruch [SMTP:jpeterruch@HOTMAIL.COM]
Sent:   Tuesday, December 21, 1999 8:01 AM
To:     vanagon@GERRY.VANAGON.COM
Subject:        HEADSTUD HORROR!

Don't read this with the lights out... it could happen to you!

Twenty some hours into a both-sides head gasket job (including resurfacing
of the old mating surfaces etc)... first side done... going into the final
torque sequence (anicipating the sound of the engine firing on the first
attempt)... at the specified 37 ft. lbs.... out of the dark and gloomy
nothing... PING!! and my wrench goes slack.  I knew it wasn't good.

I had noted that the head studs didn't look so good and that if I ever did
this job again, I might have to replace them.  One of them (number 2 in the
torque sequence) failed.  It broke way down near the crankcase... before
any
threads that might be there.

I am thinking about threading the hole in the head that the stud passes
through and simply plugging it.

Questions:

1.  What are the chances of my getting away with this "plug plan".

2.  If I have to replace the stud(s), do I have to split the crankcase?

3.  "To me -- to me -- why do these things always happen to me?"

Thanks for any help anyone can provide.

Still smiling (amazingly)

Jim Ruch
'85 Weekender; "Snugvagon"
Alfred, NY
______________________________________________________
Get Your Private, Free Email at http://www.hotmail.com