Without seeing the knife, my best suggestions are 1) check to be sure that the round tabs on the back spacer are properly seated in each liner when you r/a the knife, and 2) be sure that the spring and lockbar fit flush against both liners. No gaps, in other words. The D4s I've handled are all a nice, tight fit when they're properly assembled, so you shouldn't be seeing any gaps down the back of the knife.
BTW, the round tabs on the spacer can give you fits. I've found that the best way to get things back into place is to r/a the knife w/o the blade so that you can fit everything together with no stress on the spacer or lock spring. Once the knife is back together, but not tightened down, you can put a drop of lube or oil on each side of the blade tang to hold the washers in place, and then slip the blade and washers into the handle. Push the pivot through to hold them and then put the pivot screw in. Tighten everything down the necessary amount,and you should be good to go.