I recently replaced a 3 wire 30A dryer surface outlet (connected to 8-3 Alum, ugh!) with a 4 wire 30A outlet. I roughed in a 4" sq box and 1 gang plaster ring. The drywall was hung, taped and painted. I then tried to insert the outlet and found that it was slightly wider than the 1 gang opening. Is this common?

I had to adjust the width of the opening with linemans pliers and now the drywall needs some work.

Thanks