Issue After Pro Grille Installation

Strange issue: seeking ideas or remedy:

Background: I installed an after-market grill in my 2015 Tacoma yesterday. Stock grille came out with no problems. (I have had it out previously to install the outside sensor for an auto-dim mirror with temperature display, and to replace one of the horns.)

I pulled the stock OEM grille out with no issues. I removed the stock grille insert and installed the Pro insert into the stock surround with no issues. Everything went fine. No broken tabs on either piece. It was getting dark so I closed the hood and called it a day.

The Issue: I had noticed after I took the stock grille off that the sensor wire for the mirror was a little loose and wanted to secure it better. This morning I removed the grille push clips and the two bolts on the top; The grille top black clips at the headlights and the two bottom ones slid out, but it took a bit more effort than before that morning. I tried to finish removing it the but bottom flat tabs that go into the bumper slots all across the top of the bumper would not slide out at all. With a little effort I succeeded in getting two of tabs at the very right nearest drivers headlamp -almost- out, but it was obvious that any further force to pull it out would break things. I always completed the removal by grabbing the sides of the surround near the two false vents at the bottom next to headlights. I nudged it back in at the bottom on either side and pushed it home on the top and everything poped right back in. Repeated the above x2: no change. Checked all my work, nothing looks wrong. I can see the grille tabs at the bottom above bumper in place through the bumper slots and the grille itself is lined up evenly with the front edge of the hood, headlamps, etc: perfect gap all around.

Any ideas? Thanks in advance!