Thanks for the responses.
As for the box, it is a double "old-new" box. It is basically a plastic mudring, with no back. It attaches to the sheetrock.
As for removing the circuit board - no can do. The backs are soldered on, so I can't unscrew it.
The problem is not with the box, but the way the wires are held by the screws. I guess its hard to explain.
Imagine this, the screw posts are on the side...so even if I tighten it the best I can, and I go to put the plate in the wall, the wires will bend since the hole is on the side of the plate...the wire essentially is at a 90 degree angle...
Does that make more sense? I might have to take better shots of the plate. Let me know.
Thanks.