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Congratulations on tracking down the problem and fixing it! Every time you work on something you learn something new.

Sorry, it's been several years since I removed the pan and my memory isn't what it used to be. I don't remember any particular problem with the removal, but if you are having problems, I probably did as well. I doubt if there is any permanent damage to your transmission since you haven't...

TranSynd is a very good transmission fluid, but only has one advantage over Dexron 3, according to Allison. You can go further between fluid changes with TranSynd than with Dexron 3. Dexron 3 is the recommended fluid for the 1545 transmission with TranSynd also acceptable. Motor oil works...

I suspect you are correct about the pickup. Nothing you did changing the fluid should have caused this. I would drain and pull the pan and hopefully find the pickup was the problem. Did you drain the torque converter? If not, you are mixing the expensive TranSynd with whatever unknown fluid...