Broken Outlet Box Screw Hole

Repair or Replace a Broken Outlet Box Screw Hole


Dear Mr. Electrician:  How do I fix a broken outlet box screw hole?

Answer:  To fix a broken outlet box screw hole, I usually replace the electrical box with an old work plastic electrical box.  However, other options have come out that change the fixing method in some cases.

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Below are photos and details of how I replaced an outlet box with a broken screw hole in a kitchen backsplash with ceramic tile.

BROKEN OUTLET BOX SCREW HOLE REPAIR

There is a product now available that would have made the replacement of the existing electrical box unnecessary.  I haven’t used it yet, but it is an easy fix to a broken screw hole.  Look at the G-Clip for a simple plastic outlet box screw hole repair.

There are few options for repairing a broken screw hole on a plastic electrical box.  My standard choice was to replace the electrical box.  The G-Clip gives me the option to repair it if possible.  Sometimes the electrical box is broken more than just the screw hole, so it would need replacing.

REPLACE THE BROKEN OUTLET ELECTRICAL BOX

Close shot of a broken outlet box screw hole on a plastic outlet box mounted in a kitchen backsplash wall
Close shot of a broken outlet box screw hole on a plastic outlet box mounted in a kitchen backsplash wall.

The bottom screw hole on the above outlet box is broken off.  Because of how these plastic boxes are constructed, there isn’t any material left behind to screw into.

I used an old large flat head screwdriver to pry the broken screw hole outlet box away from the wall
I used an old large flathead screwdriver to pry the broken screw hole outlet box away from the wall.

I use a large old flathead screwdriver to pry outlet boxes away from the wall stud.  They tend to pop out easily.

Knipex high leverage diagonal pliers were used to cut the nails on the outlet box still in the wall
Knipex high-leverage diagonal pliers were used to cut the nails on the outlet box still in the wall.

I use my Knipex High Leverage Diagonal Pliers to cut the screws on the outlet box in the wall.

The old broken screw hole outlet box has been completely removed
The old broken screw hole outlet box has been completely removed.

The existing opening in the wall was a little too small to remove the old broken outlet box so I just let it drop inside of the wall.

I used my RotoZip rotary tool with a tile cutting bit to enlarge the opening for the new outlet box in this tile back splash
I used my RotoZip rotary tool with a tile-cutting bit to enlarge the opening for the new outlet box in this tile backsplash.

I used my RotoZip rotary power tool with a tile-cutting bit to enlarge the outlet box opening enough for me to get the new outlet box in the wall.  It was made more difficult because the wood stud in the wall was a little twisted.

I had to make the opening in the tile larger than I usually would have to squeeze the new outlet box into the wall.  Fortunately, I have a collection of tile-cutting bits for jobs like this.  My RotoZip also has a small circular saw attachment for cutting wood, metal, or tile with the appropriate blade.

The existing outlet wires in the wall are ready for the new outlet box
The existing outlet wires in the wall are ready for the new outlet box

I put some electrical tape around the cable’s outer jacket in the wall because the wire clamps in the box would push against the wires.

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A newly installed plastic outlet box that replaced an outlet box with a broken screw hole

Above is the newly installed old work plastic outlet box that replaced a broken screw hole outlet box.  The new old work outlet box is installed with the existing wiring, which is a little short.

The new outlet box with wire pigtails added to the existing spliced wires
The new outlet box with wire pigtails added to the existing spliced wires

I spliced the wires together by twisting them with my linesman pliers and twisted pigtails on the ends.  A screwed-on wire connector finishes it.

New outlet box with wire pigtails ready to connect to a receptacle
New outlet box with wire pigtails ready to connect to a receptacle

I folded the wires into the back of the old work outlet box and trimmed the pigtails for the new GFCI receptacle to be installed.  Most electrical receptacles in a home must now be tamper resistant.

A GFCI outlet connected to wire pigtails in a newly installed outlet box
A GFCI outlet connected to wire pigtails in a newly installed outlet box

A new GFCI electrical receptacle is attached to the pigtails. 


A new GFCI outlet was installed in the new outlet box that replaced the broken screw outlet box
A new GFCI outlet was installed in the new outlet box that replaced the broken screw outlet box.

The ears on the GFCI electrical receptacle have been cut off so that the receptacle fits nicely into the notch on the old work outlet box.

A new GFCI outlet and wall plate installed on a new plastic outlet box that replaced one with a broken screw
A new GFCI outlet and wall plate were installed on a new plastic outlet box that replaced one with a broken screw.

Click here to see more blog posts of mine about switch and outlet boxes.

My blog post about grounding outlets and switches may interest you.

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