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I bought a USB PCI card for my MDD, and it's about 1/4" too big to screw down tightly. The side door will shut fine, though. Is this going to work all right, or should I find a new card?
There are defined standards for PCI cards. If it's that close the chances are the card isn't seated properly.
I would say check the "key" of your PCI card to see if you have push your card properly. If you look at where the connection point is there is a "missing" plastic bit called the "key" which is designed so that you cannot accidentally put the card the wrong way.
Now if you have pushed the card all the way, you would not be able to see any gaps between the card and the PCI slot on your computer in the "key".