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Basically you're just driving a diesel-to-noise converter at that point :). The game doesn't model blown engines from excessive RPM, no. In reality modern turbodiesels are RPM limited anyway (modelled in the game also, btw) and you'd be pretty hard pressed to blow an engine through excessive RPM (you'll be causing excessive wear, though - not sure if this is taken into account in the game's engine wear accumulation).
You're more likely to blow a modern turbodiesel by running too LOW in the RPM range for too long (down in the peak torque range), where they tend to heat up significantly when loaded up (may burn valves or pistons, etc). This isn't modelled in the game.
Best advice I can give you for the gear changes is: Practice, Practice, Practice :)
The game could do better in a couple or so small ways, but overall there's only so much you can do to make realistic seeming actions from a very much less than realistic hardware environment.
I would agree that shifting at realistic RPM ranges appears to be more difficult than at the higher ranges in the game - the timing seems to get closer the lower down in the range you make the shift. That may even possibly be a bug.
As for the engine, I've noticed there's an inverse correlation between engine torque and engine inertia that really shouldn't be there. The more torque the engine has, the lower the engine's angular inertia appears to be. If anything though, this makes gear shifts easier with the lower powered engines, not harder (ie, the shift timing closes up more with more engine torque).
From a personal perspective, I don't have any real problems with the gear changes. Agreed that improvements could be made, however there's not an awful lot of room there owing to the general limitations of the hardware.
with older two stroke diesels such as the Detroit 6V, 8V, and 12V engines, your shift point for an upshift is between 1800 and 2100 rpm and for a downshift is 1400 to 1600 rpm, provided the torque curves are correctly modeled in the engine files... if the torque curves are not modeled in the engine files then the game treats all as modern four strokes...