Development Gag: thanks to the previous season using the name "Galaxy Gliders" for vehicles that turned into cycles (thanks to Added Alliterative Appeal), the bikes of this season got named Astro Cycles instead (PRiS bandied the word "Astro" a few times, including the name of the Megazord).
Fan Nickname: The Ranger suits for this season has been nicknamed "The Charlie Brown Costumes" because of the signature squiggly, pointed black line across the torso and around the cuffs of the boots and gloves.
Missing Episode: "Forging a Friendship", the "Air Force One on the Megaship" episode with Cassie and Maya, was discarded after Patricia Ja Lee's contract dispute with Saban Entertainment forced her off the show. A transcription of its script was eventually leaked to the fandom and confirmed authentic by the writers.
Old Shame: Danny Slavin is probably the greatest example of Creator Backlash in Power Rangers. It's believed he only took the role of Leo to pay for law school and has retired from acting since. Nasty behind-the-scenes crap that went on while filming the Lost Galaxy/Lightspeed Rescue team-up the following season only widened the gap (basically, the producers tried to screw over Trakeena's actress Amy Miller out of her paycheck; Slavin literally walked off the set alongside Miller in protest of this, forcing the producers to have to hire a body double for the remainder of his scenes and do their best to avoid showing his face during the episode). It took practically a miracle (and the producers calling in personal favors) to get him to appear in "Forever Red", and he's repeatedly turned down numerous invitations to appear at Power Morphicon. Which makes him accepting his Megaforce cameo invitation all that more bizarre.
He has announced that he will be attending Morphicon 2014 as well as the Phoenix Comic-con. That, combined with his accepting his Megaforce cameo, may mean he has moved on...
It's also worth noting that this series also recycles several monster costumes from previous Power Rangers series (some unused) as well as some from its sister series, Big Bad Beetleborgs.
Furio, the villain responsible for petrifying all of Mirinoi in the season premiere, was the monster form of Dr. Hinelar, the main villain of Denji Sentai Megaranger. That's largely the reason Furio isn't around too long, he wasn't in Gingaman.
Romance on the Set: Between Reggie Rolle (Damon) and Amy Miller (Trakeena). They are happily married to this day.
The cast was also promised a reunion movie, they never got it. Also in the team-up with Lightspeed Rescue most of the plot centers around a little girl than the actual Rangers. This lead to Danny Slavin and Amy Miller storming off the set, refusing to come back to the franchise (except for a single appearance in Forever Red, and the cameo in Super Megaforce noted above, Slavin has refused to have anything to do with the franchise, even refusing to attend conventions for many years. However, that all changed in 2014 when he finally decided to attend conventions, with the 2014 Phoenix Comic Con being his first appearance in such events ever — and has since appeared in other conventions, including Power Morphicon 2014; and he even plans on attending more).
Shipper on Deck: In a panel at Power Morphicon 2014, Danny Slavin revealed that he thought that Leo and Kendrix could have ended up together as a couple; he personally preferred this pairing out of the three given ship teases (the other two being with Maya and Karone). Interestingly enough, and as stated elsewhere, the writers were planning on making Leo and Kendrix an Official Couple, and in the story, they made several hints to try and establish it. But, again, Valerie Vernon had to take a break because of her leukemia treatments.
They STARTED with having to turn a nature-themed Sentai into a space themed one, due to the success of Power Rangers in Space.
Then, early in the season, the Lights of Orion arc began, and it's near incomprehensible, because episodes were still being filmed in the week before their airdate.
When that finished, they began an arc involving the Galaxy Book, which would tie in with the two carrier Zords (which actually DID resemble the space theme to an extent, but they were rarely used in the source material so there wasn't a lot to work with), but then Valerie Vernon developed leukemia. Her character, Kendrix, was heavily involved in the plans for the Galaxy Book, which meant that arc had to rapidly be rewritten.
The original plan was for Patricia Ja Lee, the Pink Ranger from In Space, would take over. They filmed the hand off and an episode with her joining the team (which was an American-footage exclusive episode, referred to occasionally as 'Air Force Oneon the Megaship'), but then, due to pay issues, Patricia Ja Lee walked off the set. She was quickly swapped in with Karone, requiring ANOTHER two American-exclusive footage heavy episodes.
Still TRYING to do something resembling their originally planned arc, they send Terra Venture to the Lost Galaxy (the one in the title they supposedly were supposed to be heading towards). It turns out as essentially a Filler Arc, likely incorporating as much Sentai footage in order to save money for the finale.
Then, the series is pulled before the finale airs, later put out as a 'special presentation' with little promotion.
What Could Have Been: See above, and while several great plots arose from putting in Karone originally Cassie was to replace her, there's a lot of What Could Have Been if Valerie Vernon (Kendrix) didn't get sick or if Patricia Ja Lee (Cassie) had taken the part. For instance, there have been rumors that the unused Dairanger suits would've been used for a team of "Ancient Rangers".
Actually, there was a lot of What Could Have Been even besides all that. Due to some Executive Meddling, there were a lot of last minute script changes, such as the Lights of Orion being on a cave on some forest planet, rather than on Terra Venture (which would've made a lot more sense.)
The cast was originally going to reunite for a full length Lost Galaxy movie. Instead, they got a mediocre 2-parter with the Lightspeed Rescue team. Interestingly, there was barely any drama (if any at all) with the Lightspeed cast and crew — except with the two-parter team-up production, and that drama was mainly due to Slavin and Miller's previous falling-out with executives.