I know I'm not the first to encounter this, but can't seem to find any relative posts. I have an ebay 4.0L HO header, and the flange is 7/16". The flange on my stock manifold is 1/2"...will I have to make some 1/16" shims to get this work? I don't have my intake manifold hereright now to see how it all fits. Maybe I should cut some 1/16" thick washers and tack weld them to the flange?

 

Don't do anything till you know how thick the intake manifold is...don't assume. Sounds weird tho...

 

I ran into this issue with the 99+ intake swap, If i was home with all my tools I would have ground down the header to match the intake but I wasnt. Simply bolted it together and checked all the bolts like 1000 miles later. No issues with me so I saw no need to take it apart to grind it down

edit: mine was way more off then 1/16th too