Has any one on here done the swap. I have been looking at doing this more and more, but can't find the info if the trannys are the same and what other parts need to be changed. I was thinking about doing this because my friend imports JDM engines all the time and he said he could get me one if I wanted. Part of the reason I want to do this is because I will be doing a lot of towing with my Montero and I am a big fan of biofuels. any help would be great

However big fun of diesels I'm It's not an easy swap to say the least. $$$$ too. If you really need towing ability It would be a lot easier/cheaper to swap 4.9 ring gear in. (Although Angelo might disagree) It would help tremendously anyway compared to your current stock 4.272.
If you are in emission checking state you might thing twice about such swap especially in light of potential 25k fine (yes 25$$$) for installing uncertified imported engine.

hey now.. <img src="/forums/images/graemlins/nana.gif" alt="" /> I never really disagreed, just wanted to show others that 4.27 gears in a Gen 2.5 can do everyday driving fine, but yes I know, it helps to have the gears which I couldnt get at the time. You can drive with your factory gears for awhile, but you will def need to upgrade to 4.90's. Like Alex said, the cheapest way to go is the upgraded gears. You'll be able to trail things like you would at factory settings if you ever go with bigger tires, if they are smaller than a 35, you'll get better results. Good luck,
Angelo

the easiest swap is 4D56 2.5L turbo intercooled, the reason for this is that you dont need an ECU you can wire most everything easily. the transmissions are different between diesel and gasoline engines, but you can pick up a complete 4D56 with transmission and t-case for about $2800.00 this is the swap i'm going to do once my 3.5 is worn out. heres a link 4D56 intercooled turbo

I thought the 4m40t was mechanical injection and didn't use an ECU? And aren't all the diesels the same bellhousing as the 2.6L? I know the 4d56 is the same bellhousing...is the 4m4x series a different bell?

4m40 does not have ECU 4m41 does. Pump chnged from mechanical to electrical some time late 90s. (I'm not so clued up on the 4m40, since my transplant was a 4m41).

Dunno about the 2.6 bell-housing, but matching any tranny to a 4m40 or 4m41 is simple, due to the fact that the BH bolts to a steel plate, which is easy to have made up. See pics (of my 4m41 transplant). The length of the spigot shaft becomes the critical issue.

Transmissions are similar, but first price is to buy a complete drive train from your friend - engine + transmission + transfer case.

See this is where I get lost because some of the other boards for Monteros that are over sea's say that the tranny and transfer case are the same when it comes to the 3.5 and the 4m40t using the same tranny. I also thought that the 4m40t would work because it mechanical. I know the swap will take some time but I know I can do it. Hell me and a few friends put a 5.9 cummins in a 2500 chevy and its working great.

They might say the transmissions are the same but the overdrive ratio is differant as well as the bellhousing. I am quite sure the shift points are calibrated differently also.
You should be able to get the bellhousing and the other stuff might not matter.
The 4M40 came out of a montero, it should be able to go back in one.

Well I am going to keep looking for more info. Once I find all the info I need, this will be my winter project <img src="/forums/images/graemlins/smile.gif" alt="" />

the 2.8 engine box uses an ecu to control ratios and shift points its a fuzzy logic or learnibg tran and will adapt to the driver the 2.5 is much simpler just mechanical the boxes are diff as are the tfr cases and axle ratios and there are also several ratios avail on each model as you probably know, i wouldnt rec the swop personally due to the huge power loss you will get the 3.5 has 220+bhp the 2.5 109bhp i have a jdm 2.5 and whilst its a great plodder when towing hills kill them even when solo a big hill slows you down considerably be far better running the 3.5 on lpg (if its legal over your way) 0 emmissions much cheaper to buy (here at least) and no loss of power