One of the common problems with Reatta headlights is failure due to worn bellcranks. The bellcrank is the arm that is bolted to the headlight gearbox that pushes the headlight assembly up to expose the headlight. The following instructions will describe how to repair the bellcrank.

If you have not rebuilt the headlight gearbox recently by replacing the nylon rollers, this is the ideal time to do so. Instructions for repairing the gearbox can be found here .

These instructions assume you have the headlight assembly removed from the car and the bellcranks removed.

Tools and parts you will need:

• Vise Grips pliers
• Center punch
• Hammer
• Electric drill (or drill press)
• 3/8" drill bit
• 5/32 drill bit
• 10-32 tap
• 2 - 10-32 set screws with flat nose.
• Allen wrench set
• Blue Locktite

The first step is to evaluate the bellcrank and decide if you should drill the hole in the bellcrank out to make it completely round or to leave it as is. If your bellcrank flats inside the hole are only slightly worn you can get by with only drilling and tapping for new set screws. Drilling the hole out as described below is the strongest repair option.

If the flats in the hole are worn badly I would recommend drilling the hole out using a 3/8" bit. If you do not drill the hole out the set screws will only contact the round portion of the shaft and will not be as secure as it would be if you have a round hole. Drilling the hole in the bellcrank to a 3/8" round hole allows you to turn the bellcrank 90 degrees and run the set screws in against the flats on the output shaft of the motor.

The bellcrank must be held firmly while drilling the hole. Injury could occur if the drill bit hangs !!  The bellcrank could come loose and start to spin around with the drill bit.

The photo below shows a bellcrank that is worn but has not been completely rounded out. Any bellcrank with more wear to the flats than the one shown below should have the hole drilled out with a 3/8" bit.


Once you have made a decision on how to deal with the hole in the bellcrank you can proceed to drilling and tapping the holes for the set screws. Center punch the bellcrank on one side as a guide so the set screw hole will be aligned with the centerline of the shaft. Then using a 5/32" drill bit drill a hole through the first side of the bellcrank and continue on through the other side of the bellcrank.  See the photo below.

It is important to keep the drill bit running at a 90 degree angle to the centerline of the hole. (See photo below.)

After you have the holes drilled in the sides of the bellcrank, remove chips and debur the holes. Holding the tap in line with the centerline of the shaft, tap the holes with a 10-32 tap as shown in the photo below.

If you have never used a tap before, do not try to run the tap all the way in the hole in one motion. You need to turn the tap in about 3/4 turn and then backup 1/4 turn. Keep repeating that procedure until the hole is tapped. NEVER try to force a tap in if it hangs. Back the tap out and try again.

When you have the holds drilled and tapped for the set screws, slide the bellcrank back over the headlight gearbox shaft. Apply a small amount of Blue Locktite to the set screw threads and screw them into the bellcrank part way.


Next install the bellcrank onto the headlight gearbox shaft and tighten the set screws against the flats (if you drilled out the bellcrank holes) or against the round part of the shaft if you left the flats in the bellcrank.

The set screws should be tightened down with equal opposing force on each side of the shaft for best results. Do not over tighten!

Now reassemble the headlight assemble in you car and you should have worry free headlight operation for years to come!

Thanks to members of the AACA Reatta forum for  the photos and instructions.