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hmm...when I plastidip my ac trim pieces, I didn't take off the entire vent. I just pulled out the trim piece.
Did you try rotating the part to see if it clips in any other way? Since the ac vent sits at a slight angle to the dash. Or..when in doubt, just mash the sucker back in in clip holders. I I took a bunch of trim pieces off and on many times and the hard plastics can surprisingly take a beating.
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