Color issues with Business Cards and Vista Print (Ps & Ai)

So I use Vista Print for my business cards, quick, easy and affordable.
I had some graphics that could not be reproduced in Ai very easily so I downloaded the Vista Print .PSD template and worked off of that.
When the cards came in color was correct but the font was not good. Not very clear and there was digital noise around the edges, so not crisp.
So I downloaded the Ai template from VP, reproduced the card in Ai and just dropped the logo in on the canvas and redid all the text in Ai.
When I got these cards in, the font looked much better and crisp, but all my colors were off. My navy blues were not navy-purplish looking. Side by side, it was a big difference.
I didn't change any color profiles I even made sure the CMYK values from the original photoshop file matched exactly to the Ai file.
So question is, why would the Ai file print differently if the CMYK color values were the exact same? It makes no sense to me. Was it perhaps how I saved the Ai files? There are so many options when saving it's a bit overwhelming.

Believe it or not, the Vista Print cards could be color copies.  Try and post a screen shot of each card so we can see the differences.  Not sure how you proofed the card redo out of Illustrator and/or what you used to print the redo card.  The problem with Vista Print is quality control.  You say the card color is accurate in the VP cards.  However, did you proof the card before sending it to VP?  If you did, how?

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