Crazy header in coffee-stain theme

Can anyone help – I’ve been using coffee-stain theme modified. I am using this theme on 2-3 sites – just changing my header.

With a new 2.5 upgrade I again changed the theme to coffee-stain and no header appears. The header.jpg is there – them theme correctly references it. I can download the theme from a working 2.5 site using that theme and upload with no changes and still the header does not appear – the body background, footer – everything else works – just not the header. I have uploaded 2.5 again same as I have used for another 6 sites. I have deactivated ALL plugins and still no header. Another site on the same server works fine? So, I am completely at a loss. Anything in the database that could do this. I suspect that this site may have been hacked – but the only original thing left is the database – all other files have been changed?