Most likely it has to do with your layout constraints. The reason you are seeing a difference is because in one case (called directly from onCreate() ) the text is set before the views are laid out, so the TextView height is set to match the content inside. In the second case (from the Thread ), the text is set after layout is complete, and TextView does not adjust its size to match new content unless its LayoutParams explicitly tell it to do so.
If you pasted your whole layout we could try to do some more debugging. TextView.setText() ends up notifying the parent container and apparently this behaves differently depending on when it is called.
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