How to Install a New Breaker in an Existing Main Panel

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    • 1). Turn off the power to the breaker box (panel). Open the breaker box and remove the cover around the existing breaker with a screwdriver. Feed the new cable from the circuit into the breaker box through one of the holes in the box. These holes have a knock-out covering the hole which is removed by prying it off with a screwdriver. Clamp the cable into place with a cable clamp which matches the other clamps in the box. If a matching clamp is unavailable, the wire can be fed through the same hole as an existing wire by loosening the existing clamp up enough to accommodate the second wire. Feed the new wire through, and then tighten the existing clamp.

    • 2). Split the sheathing all the way from the end to the clamp with a sharp utility knife exposing the wires inside. Route the ground wire (the bare wire) to the ground terminal in the box. Cut the excess (if any) with wire cutters and attach the ground wire to the terminal with a screwdriver.

    • 3). Route the white wire from the cable through the box to just reach the neutral buss (the terminal where the other white wires are attached). Cut the excess white wire from the cable to the appropriate length. Strip 1/2 inch of the insulation from the end of the wire with wire strippers and attach it to a vacancy in the neutral terminal (buss) strip.

    • 4). Route the black wire from the cable to the location where the new breaker will be. Cut the wire to remove excess and strip 1/2 inch of the insulation from the end. Attach the bare end of the wire to the terminal of the new breaker with a screwdriver.

    • 5). Set the new breaker to the "off" position and insert it into the panel and snap it into place per the instructions included with the breaker. Remove the knockout from the panel with pliers and/or screwdriver to create the opening through which the new breaker will protrude.

    • 6). Re-install the breaker cover. Restore power to the breaker box. Set the new breaker to the "on" position.

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