Transmission sensor with overmolding and method of manufacturing the same

An apparatus comprising:

• a variable reluctance sensor element including a wound wire, a magnet, and a pole piece the sensor element including a first end;
• a cap positioned about the first end of the sensor element the cap including at least one groove defined in the cap;
• and
• an overmolded shell encapsulating at least a portion of the sensor element and contacting the groove effective to provide a seal between the shell and the cap.

A method of overmolding a resin shell about a variable reluctance sensor element including a pole piece, a magnet, and a wound wire, the method comprising:

• positioning a cap at one end of the element;
• placing the element and the cap in a mold;
• maintaining the position of the element within the mold using at least the cap;
• and
• introducing resin into the mold effective to encapsulate the element.

A method comprising:

• providing an assembly including a bobbin, a wire wound about the bobbin, a magnetizable core disposed at least partially within the wound portion, and a magnet positioned adjacent the magnetizable core;
• positioning a cap over at least a portion of the magnet;
• placing the assembly and the cap into a mold;
• introducing resin into the mold effective to encapsulate at least a portion of the assembly.