Notice the outer lip of the seal on the pinion shaft. I don't know if this will help you, but imediately after that lip, the shaft begins to taper down. Is yours just after that taper on the flat (sealable) portion of the shaft? If so, that would be an issue, but not by much. More to the point; however, any chance the inner seal hyperextended on install? So... Hylomar used? Inner and outer threaded ring threads spotless (wiped with acetone and debris blown away)? Pinion seal correct depth?
Here's a pic of mine before I installed the nut. See the taper and how close the outer lip seal is?