(Before I begin: The question uses the function $\lambda_f$ but doesn't define it. According to Fremlin's Measure Theory, which OP identified in the bounty comment as the source of the question, it's a set function on the set of half-open intervals, such that $\lambda_f(\varnothing) = 0$, and such that $\lambda_f \, [a_j, b_j[$ is the summand in the definition of $\lambda_f^*$ for $a<b$.)
There isn't anything wrong. The argument continues to work because the most important ingredient isn't any minutiae of $\lambda_f$ but rather the way we defined $\lambda_f^*$ from $\lambda_f$ as the infimum of sums of outputs of $\lambda_f$ over covers. The only property of $\lambda_f$ that we needed was its non-negativity, which we have regardless of whether $\lambda_f \left[a,b\right[$ is $\lim_{x \uparrow b} f(x) - \lim_{x \uparrow a} f(x)$, $f(b) - \lim_{x \uparrow a} f(x)$, or $f(b) - f(a)$.
It really doesn't take much to get an outer measure through this method: The same argument shows that given any triplet $(X, \mathcal C, \mu)$, where $X$ is a set, $\mathcal C \subseteq \mathcal P(X)$, and $\mu \colon \mathcal C \to [0, \infty]$ a set function(!) such that $\inf \mu(\mathcal C) = 0$, the set function
\begin{align*}
\mu^*\colon \mathcal P(X) &\to [0, \infty] \\
S &\mapsto \inf \left\{ \sum_{j=0}^\infty \mu(A_j) \;\middle|\; A_j \in \mathcal C,\, S \subseteq \bigcup_{j=0}^\infty A_j\right\}
\end{align*}
is an outer measure. For a quick reference, Wikipedia states a slightly less general version (they require $\varnothing \in \mathcal C$ and $\mu(\varnothing) = 0$) attributed to M. E. Munroe's Introduction to Measure and Integration.
The belief that "this argument is not supposed to work" might come from a misinterpretation of Fremlin. In Exercise 114X(a), he first defines $\lambda_g$ and $\theta_g$ ($\equiv\lambda_g^*$) (here $g$ is the non-decreasing function), and then invites the reader to do as follows:
Show that $\theta_g$ is an outer measure on $\mathbb R$. Let $\mu_g$ be the measure defined from $\theta_g$ by Carathéodory's method; show that $\mu_g I$ is defined and equal to $\lambda_g I$ for every half-open interval $I \subseteq \mathbb R$, and that every Borel subset of $\mathbb R$ is in the domain of $\mu_g$.
Subsequently in Exercise 114X(b), he asks
At which point would the argument of 114Xa break down if we wrote $\lambda_g \left[a, b \right[ = g(b) - g(a)$ instead of using [the given formula
$$
\lambda_g \left[a, b\right[
= \lim\nolimits_{x\uparrow b} g(x) - \lim\nolimits_{x \uparrow a} g(x)
$$
]?
We've seen that $\theta_g$ is an outer measure even with the alternate $\lambda_g$. The "breakdown" instead happens somewhere in the second sentence of the passage I quoted from 114X(a).