Husband had to have a 2nd vasectomy

Last July my wonderful, brave husband underwent a vasectomy. I've been on the Pill for about 8 years now and we're both eager for me to get off of these little pseudo-hormones. Anyway, before doing so we were waiting for him to get 2 negative (i.e. no sperm) tests back from the lab. The first one (2 months post-operative) came back with sperm, but dr. wasn't concerned. The second one (4 months post-op) also did. Dr. said if the next one did, it wouldn't be a good sign - it would mean the vas deferens had recanalized. Sure enough, the 3rd one (6 months post-op) had sperm - a higher count that the previous two.
So my loving husband agreed to undergo a second one (dr. didn't charge a second time - said this had "never happened before in his practice" - not that I doubt him - we just seem to have crappy luck).
Anyway, we're **hoping** it takes this time (especially since he said it was MUCH more painful the second time). My question is, has anyone else ever known of this to happen? I mean, we knew going in there was a slight risk of this happening, but neither of us thought it actually would. And I'm wondering if it recanalized once, are the odds of it happening again greater? I'm worried now that even if we do get the lab results we hope for that in, say a year, it may have healed.
Sorry to prattle on so. Just anxious.
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