So what would make oil get into the lines?
A plugged axle breather will allow the pressure built up inside the axle housing to force gear oil past the o-rings on the seal housing. This is more common that many folks think, since it really does not take much to plug a stock breather, and once it has forced gear oil into the air circuit on the locker, it will continue to draw oil in. The earlier design seal housing on the ARB units was retained by three machine screws to the backlash adjuster nut on the differential housing. There were many instances of this housing not being installed concentric to the carrier, because installers were over-tightening the three little 4mm Allen head fasteners, creating a situation where gear oil would leak past the o-rings in the seal housing, causing the locker to pump gear oil. Another situation was that installers were damaging the o-rings in the seal housing during assembly.
These scenarios can be avoided by simply leak-testing the assembled unit while on the workbench and verifying that there are not any leaks in the air system. If you do not leak air, you will not pump oil. (again, as long as your axle breather is not plugged)
ARB has since, (2005, iirc) changed the style of seal housing and seals used, and made it into a floating design and uses square cut seal rings with a larger cross section. This system seems easier to install and less likely to be damaged or leak during assembly.
Overfilled diffs? Getting the truck up at severe angles?
Overfilling the diff could possibly have an effect, but you would have to FILL the axle housing, leaving no room for the expansion of the gear oil when it reaches operating temperature in order to create this scenario, and I do not know how you could do that filling the axle from under the truck. Severe angles will not have an effect on this.
Is there supposed to be ANY path for gear oil to get into the air circuit?
No. It is a sealed system. The air used to pressurize the locker exhausts back through the tube at the solenoid valve when released; it does not empty into or pressurize the axle housing.
