What Could Have Been: Very early materials suggested that the rivalry between the Wind and Thunder Rangers was supposed to play out a lot longer than it did (and possibly be the central conflict of the series, rather than a traditional villain), with kids even being encouraged to pick sides for themselves.
The Tori character may well have become a carbon copy of her Hurricanger counterpart (aspiring Idol Singer Nanami) had Emma Lahana, who auditioned for this role before becoming Kira in the following season, gotten the part instead of Sally Martin.
The plot would have seen a Civil War-style plot with the Rangers being divided between Tommy's group the Hexagon, which consolidated the Rangers under a single banner, and a rebel group lead by Jason who didn't think one person should have that much power.
The Hurricanger equivalents would have been the Hexagon's latest heroes, possibly getting their powers from Ninjor, while the Goraiger equivalents would have been on Jason's side; Bhaumik claims to have been pulling for the creation of a new, US-exclusive ranger, a female Thunder Ranger with a dark yellow suit to preserve the "two girls per season" dynamic.
The villain forces would consist of "loose ends" from past seasons, including Scorpina, Lokar, and Prince Gasket. The Monsters of the Week from Hurricanger would be reshuffled into subordinates of these characters (such as more mechanical ones being Gasket's minions), or else placed into a new faction lead by the Hurricanger villains.