Glad you got it figured, but just for clarity - you mentioned no grease movement on the lock ring? So the seal isn't riding on it at all, and you have no leaks?
So here's a thought: have you tried switching the axles side to side? I'm new to this site and the 4runner world but I'm an experienced Jeep guy and used to be an ASE Master Auto tech. Once I couldn't get one of my axles to seat entirely on a Dana 44 and it was because one shaft was 1/4 longer than the other. I was putting them back in the wrong sides. I know it's a 'Yota axle and not a Dana but it's worth a shot if you're still scratching your head over this.
EDIT: so you got it, and I'm late to the game. Good jorb there.
So here's a thought: have you tried switching the axles side to side? I'm new to this site and the 4runner world but I'm an experienced Jeep guy and used to be an ASE Master Auto tech. Once I couldn't get one of my axles to seat entirely on a Dana 44 and it was because one shaft was 1/4 longer than the other. I was putting them back in the wrong sides. I know it's a 'Yota axle and not a Dana but it's worth a shot if you're still scratching your head over this.
EDIT: so you got it, and I'm late to the game. Good jorb there.
I read through this post when i was looking for something else. Maybe i can help someone else looking for information. the picture in post #5 showing the abs ring and inner race is an example of exactly how not to do it. they are pressed on way too far. the inner race is there to ride inside the axle seal, in this picture the ring is not even going to contact the seal. the abs ring is pressed over the axle clip holing the outer ring in place. this makes it a real pain in the ass to get off in 6 weeks when the rear end grease starts leaking into the brakes. the inner ring should be roughly 3/16" down from where the polished part on the axle starts.