You pay income taxes on that money plus a 10% penalty. So, if you make $50,000 a year and your 401k balance is $40,000, for 2006 you'll be taxed based on income of $90,000, PLUS the 10% penalty on the $40,000 from the 401k. And more important than that, you put your retirement at risk. Compond earnings on investments is what make retirement possible for most people, you do not want to lose that unless there is truely no other choice.
I'd advise you cut your budget to the bare bones and see how far that will get you. Cut out everything that isn't esential. No cable, no personal cell phones, no eating out, no extra treats when you go grocery shoping (pop, cookies, candy, chips ect. It's all junk anyway, think of it as a family diet!

) conserve on energy/water to get utilites down, shop for new insurance (house, car, etc.) with higher deductables. If you want help with slashing any part of your budget, especially groceries and household items, go to the Budget Board on these forums. Very nice, helpful people there full of budgeting advice, including people who know more about the penalties of cashing out a 401k, if you want more info on that.
Good luck!
