Transmission sensor with overmolding and method of manufacturing the same

A method of manufacturing a transmission sensor comprising:

• providing an assembly including a bobbin having a cavity formed in the bobbin, a wire including a wound portion wound about the bobbin, a magnetizable core disposed at least partially within the wound portion, and a magnet positioned adjacent the magnetizable core;
• inserting a plug into the cavity;
• positioning the plug and the assembly into a mold;
• introducing resin into the mold effective to encapsulate the sensor assembly;
• first removing the plug and the assembly from the mold;
• and
• second removing the plug.

A method of overmolding a resin shell about a variable reluctance transmission sensor assembly including a bobbin, a conductor wound about the bobbin, and an aperture defined at an end of the bobbin, comprising:

• connecting a positioning tool to the assembly at the aperture;
• placing the assembly and the positioning tool in a mold;
• maintaining the position of the assembly using the tool;
• introducing resin into the mold;
• and
• allowing the resin to set;
• wherein the introducing is effective to substantially hermetically encapsulate a portion of the assembly excluding the aperture and to form an outermost surface of the sensor.