Here is a perfect example of what I am talking about.
You see this same size difference when you compare a original old Ford/IH black CPS to any of the new OEM ones from both companies.
The smaller one is straight from Ford as part of the recall. What many call the grey. The one next to it is a Borg Warner BWD CSS1603
(BWD CSS1603 purchased from Advanced Auto with online discount TRT30 for $18 and change. That code is good for 30% off any order of parts. I order online for in store pickup. No shipping cost still get the online discount and pick it up immediately from whatever local store has it in stock that I choose.)
Sorry it was such a grainy pic. Did not have my camera with me. Another thing which maybe hard to noticed but has been shown thru breaking apart the units. If you look at the end where you see the radius edge. You will notice the Ford unit on the left has a thicker radius size. This is all solid plastic between the magnet and outside of the housing. The right BWD is about half the thickness very thin. Thus not only is the magnet stronger but it does not have to go thru more plastic and that also puts it that much closer to the actual gear pickups.
These are the big differences you see between the good and poorly working sensors. While in some engines they may not appear to make any difference in the engines where they do it can be quite dramatic. Anywhere from 1-3+ mpg has been documented. Idle quality and throttle crispness improvements. Going from failures 2 or more cylinder failures on Contribution/Perdels testing to none. So I am not per say recommending any specific brand or model of CPS as it seems a Manf can nd will change from time to time. What I am recommending is to check physical characteristics, mentioned above, of them before you purchase or use them to help find the one that will offer the better performance. Color again no longer has any standing what so ever that I can tell in the aftermarket of these sensors.
This BWD happens to be what I would call a charcoal or darker grey with the ford being a lighter grey by about 2 shades.
I add Dielectric grease into the connector during install as IMO it may prevent issues in wet weather or water crossings. I have noticed I have had some past intermittent power losses in heavy rain or after going thru water that I traced back to water getting into the sensor connector on a couple vehicles. One my own and a friends.
My explanations are very basic trying to make it simple there is much more detail of the differences inside the sensors that have effects on the performance. Credit to one person that goes by Van_350SD on TDS forum for taking the time to document his break down and measurement of various sensors. Link I posted earlier and here again. His first post post has a ton of good info as do later posts in that thread:
CPS thread