When you save a face to the library, it will include all the morphs that were injected at the time. If a morph setting is in both the face file and the figure you're applying it to, the setting from the library will overwrite the existing one. But, if there's a morph in the 'old' face which hasn't been injected into the 'new' one (and hence has no dial), that won't be overwritten, whereas you really want it to be set to zero. If you made both faces with a common set of injections, you'll be fine. If not, the easiest way (I think) is to REMove all the head morphs from the 'old' face before applying the new one, and start with a clean slate. I hope that makes sense. I found it phenomenally difficult to explain, for some reason. :)