Thanks for the update mate, glad to hear the washer sorted your issue.
I ended up biting the bullet and grabbing a new MS Driver from my LBS. Thankfuly they laughed but took a bit of pity on me and helped me out price wise. Interestingly, I can really see where the issue is with my driver compared to the new one.
Looking at the two side by side, the ratchet splines are at the same distance from the end of the driver, but the base of the new non-flanged version is 2.5mm lower than the flanged version. My LBS and I think that it's still a legit driver, but just for a DT Licensed hub where the driver is recessed into the hub-shell by a couple of mm. The bearing seal patterns are the same and the build and finish quality is top notch, which also helps in that thought.
Now just to find out which hub it's from so I can hopefully sell it on. Doesn't appear to be Roval based on the MTBR thread linked earlier, and while Syncro license the ratchet, the drivers I've searched for seem to be "standard" (aka the lip proud of the base). So that leaves Bontrager, but I can't find any decent images of the ratchet hubs, only their Rapid Drive, which is a pawl-based system.
So, what other brands use a DT Licensed ratchet setup? I'm all ears!