I installed some wire nuts, but they push back on the cover when closed

Question

I had to replace a sink disposal recently. The disposal came with a plug which my setup doesn't have, and I removed it and attached the wires coming from the wall directly to the inside of the machine with wire nuts. I turned it as tightly as I could manage, and the wires don't seem like they'll slip out (I didn't twist the wires because I faced very high resistance.)

However, when I put the cover back on the disposal, I had to press with quite a bit of force. I'm afraid this leaves the wire nuts in a condition where there is some sort of permanent stress on them.

Should I worry about this (i.e., take it back out and shorten the wires in there so the nuts rest more easily)?

Answer 1

Consider using UL-listed lever nuts such as Wago 221s. IMO they are much better for DIY homeowners than traditional wire nuts.

To address your main concern, that you have limited space in the small junction box integrated into the disposal: Lever nuts use less space because they avoid creating a large solid bulky mass of twisted wire. The wires can be cut shorter, and after attachment they can rotate within the nut so it's easy to pack the nutted wires flat into the box. They all remain flexible unlike a twisted bunch of wires.

Other advantages: They require no guess work regarding wire length or nut tightness, they do not damage wires nearly as much if removed and replaced for any reason, it is far easier to correct mistakes, they are easier and safer for dissimilar wires (almost certainly true in your case), and they do less damage to old brittle home wiring. They make it easy and (relatively) safe to perform testing on live circuits. It is harder to use the "wrong size" nut because each wire has its own lever and there are only two common sizes of nut.

They require a little practice to develop skill and avoid mistakes but not nearly as much as traditional nuts. They are far more expensive than traditional nuts but for the limited use by a homeowner they would be a bargain at 4 times the price.

Note: Please be sure your disposal is equipped to properly mount home wiring (NM, MC, whatever you have) in place of its power cord and that you do properly mount it! If not, you are FAR better off installing an outlet near by and using the original power cord.

Answer 2

You may just need to improve your technique. Pressure means stress, and that's to be avoided with both wires and housings.

• Strip cable jackets to within 1/2" of the box entry clamp
• Organize wires so they aren't tangled
• Trim longer ones to roughly match their mates
• Lay in each set of wires using a gentle S pattern across the back of the box
• Alternate direction where possible to stagger nuts

The caveat here, as some have mentioned, is that your unit should be rated for direct wiring and have the necessary facilities for it. Sticking NM-B building wire, for example, arbitrarily into an appliance not intended for that isn't wise.

Other tips for using wire nuts:

• Be sure you have the right size. Each has a specific capacity, and overlarge or undersized ones won't make good electrical contact or allow proper tightening.
• Lead solid wire with stranded wire slightly to allow for bunching
• Push gently at first, then harder
• Pre-twist if your brand of nut calls for it
• Twist until the wires begin to spiral together
• Test with a tug on each wire

Answer 3

If the wire nuts are firm and tight on the wire with no bare wire exposed it should be fine.