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The 4.0L intake ports are higher up on the cylinder head than on the 4.2L. This is the major reason for thier better airflow and higher power potential. Because of this, the intake mounts up higher on the 4.0L head than on the 4.2L head.
Now if you look at how the intake and exhaust manifolds bolt up, they share several bolts. If the intake is sitting up higher, the shared bolts will miss one manifold completely, and will not fully clamp down the other manifold.
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Ask me anything about a Cummins, I stayed at a Holiday Inn last night.
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