The problem is what I explained in post #4.
You use AutoScale which will adjust the Left, Top, Width, Height and also the TextSize.
The scale factor depends on the layout variant and the AutoScaleRate which os 0.3 by default.
If, after that, you set a 'none scaled' value like 40dip, the TextSize could be too big.
Is AutoScale not enough, you could play with the AutoScaleRate.
What layout variant are you using?
Downscaling, with AutoScale, a big layout to a small one can lead to bad results.