Hey, BC
I shoot both the 400mm 4.5 and the 400mm 2.8 TC, and the 4.5 is very close in sharpness to the exotic 2.8 — both lenses are exquisitely sharp.
So the 400 4.5 should get you razor sharp results, even wide open.
As others have noted, I’d test the lens under controlled conditions — high shutter speed, stable platform, and outside away from heat sources that can cause atmospheric distortion.
I suspect that you’ll find the lens is fine, and then you can start narrowing down what the problem was with those particular shots.
Good luck!