I am currently repairing my pop up roof with some of the same issues.
First, the design of the roof structure is flawed. The roof latches pull out on the aluminum skirt breaking the caulk joint and let water into the slot holding the plywood backing. With nowhere to drain, the water wicks into the plywood until it disintegrates. Then things start bending and falling apart. I am replacing the plywood with PVC trim and am about half done.
Second, The brackets on the back should be square when mounted. As mentioned, there is a torsion bar (with a hex head) inside the top tube that connects to the bracket. Over time, the tension and jostling causes the brackets to twist in the plywood. I plan to remove the roof, refit the brackets and attach a 7 ft. steel bar across the back to secure them from twisting. I just need to visit a friend with an overhead beam and chain hoist to lift the roof.
Check the internet for "heco roof repair", and "how to deal with the torsion bar lift system". There is one good instruction sheet written by a former TC manufacturer on how to properly torsion, adjust and reconstruct the Heco system.
Hope this helps,
