95 OBD1 conversion to 96 OBD2?
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From: Napa
95 OBD1 conversion to 96 OBD2?
Ok so this isn't happening anytime soon (maybe next fall if I'm lucky) but I need to replace/rebuild the engine. The rear main leaks, the motor mounts are busted, and there is an intermittent coolant leak .... somewhere 
So the plan is to go to a yard and grab a motor. Tear it down and take it to a shop for machine work. Then probably take it and parts to shop to have it built. I'm fine tearing it down, not sure I want to try to assemble it
So let's suppose I want to go to the OBD2 system so I can use my smartphone to pull codes and look at other "neato" stuff. Can I get a list of all parts, wires, sensors, etc etc needed to make a complete swap from OB1 to OBD2?
I'm fairly confident in my electrical skills so pulling harnesses shouldn't be too bad
Either way I'm going to probably stick with an auto trans.
Once the motor is done, tranny, xfer case, and drive shafts would be next. Followed by a rear disc brake conversion. Then bushings ... or maybe do them prior to tranny work. Possibly followed by a manual hub conversion.
So the plan is to go to a yard and grab a motor. Tear it down and take it to a shop for machine work. Then probably take it and parts to shop to have it built. I'm fine tearing it down, not sure I want to try to assemble it
So let's suppose I want to go to the OBD2 system so I can use my smartphone to pull codes and look at other "neato" stuff. Can I get a list of all parts, wires, sensors, etc etc needed to make a complete swap from OB1 to OBD2?
I'm fairly confident in my electrical skills so pulling harnesses shouldn't be too bad
Either way I'm going to probably stick with an auto trans.
Once the motor is done, tranny, xfer case, and drive shafts would be next. Followed by a rear disc brake conversion. Then bushings ... or maybe do them prior to tranny work. Possibly followed by a manual hub conversion.
Posting Guru
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I think you would have to replace virtually the entire wiring harness(s) in the truck. Certainly the entire engine and drive train harness, plus the interior harness to get the OBD2 connector. It would probably be easier to get an aftermarket EFI system that does OBD2 and MAF, and use that control your engine AND transmission. Don't forget that the ECU on these trucks also controls your transmission. An aftermarket setup like this would probably give you even more cool features you could monitor on your phone or other smart device in the cab, but either way its a really big project.
Fleet Mechanic
Joined: Dec 2006
Posts: 1,925
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From: Phoenix, AZ
I'm not familiar with the OBD1 setup on these trucks because mine had the gas OBD2 stuff before the diesel swap.
I believe there are quite a few more sensors involved with the OBD2 system so it would be a pretty big undertaking. You would need a new PCM, and almost definitely engine wiring harness. Apart from that, the dash wiring harness would most likely have to be replaced as well, and maybe even the engine bay chassis wiring harness.
One thing I do know is that the OBD2 Broncos had a specific harmonic balancer that has a sensor ring on it. They don't make these, so you'd have to buy a used one which may be kinda hard to come by. I thought about replacing mine years ago but never found where to buy one new. I read that if they go bad, people get the rebuilt.
I believe there are quite a few more sensors involved with the OBD2 system so it would be a pretty big undertaking. You would need a new PCM, and almost definitely engine wiring harness. Apart from that, the dash wiring harness would most likely have to be replaced as well, and maybe even the engine bay chassis wiring harness.
One thing I do know is that the OBD2 Broncos had a specific harmonic balancer that has a sensor ring on it. They don't make these, so you'd have to buy a used one which may be kinda hard to come by. I thought about replacing mine years ago but never found where to buy one new. I read that if they go bad, people get the rebuilt.
Posting Guru
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I've been getting to know OBD2 a lot better lately, and I would recommend against this endeavor now. Early OBD2 doesn't provide access to as many "cool" features as you would think. 2011ish and up vehicles give you access to high beams, wipers, turn signals, speed, RPM, seat belt status, and all kinds of other stuff. Your not going to get anything approaching that out of a 1996 PCM. If you want detailed engine and transmission data I'd just get an aftermarket setup, there are several options out there for controlling the engine+transmission combos in our rigs nowadays.
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