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Yep the plastic did split because of diameter mismatch.
I also tried to measure the internal dia of the holes and it turned out to be 1.86mm and the screws were like 2.9, so I was thinking of getting M2 which are about 1.9mm. Interestingly its only the tibia base plate, tibia cylinder and tibia foot plate that have smaller hole size, the tibia sides, ,foot bumper holes are perfect.
Getting 4-40 in Melbourne locally is next to impossible. I tried to order from the link that you had provided and unfortunately those guys do not export to Australia.
I have printed and painted all the parts, received all the electronics already, so I am not stopping now, I will find a way to get the right screws :-)
Thanks for your quick response.