In most cases, when a cassette won't turn to lock together is it because the steel portion of the cassette is not fully seated onto the XD driver.
We make the fit between the cassette bushing and the XD Driver very snug, so that the cassette won't move and shift in use. This can, however, lead to issues during installation.
Occasionally grease on the XD Driver end under the plastic bushing can get trapped between the bushing and the driver, which stops the bushing from pressing all the way on.
Solution: Remove the steel cassette part and plastic bushing, and wipe off as much grease as possible, then reinstall.
The plastic bushing in all our current cassettes is a teflon filled delrin, so it requires the bare minimum of grease to aid installation and prevent noise.