Having been hypo for 18 years (since I was 21), i kind of agree with the op. I don't think levels always correlate to symptoms.
From a young age I always felt the cold, had very thin hair, tired etc and just put it down to going to uni, working at weekends etc etc. it was only when I started suddenly getting pains in my neck that I was diagnosed as hypo. Neck pain was the only reason I went the gp.
Before then my symptoms were not really affecting me. My tsh was 22 at the time I was diagnosed but generally I felt very well.
I was started on 25mcs and I disagree that 25-50mcs must always be too low dose.
On 25mcs my tsh went from 22 to 1.5 and stayed that way for 8 years! It was after my first child that I upped to 50 and again I stayed that way for 5 years. I now take 75mcs and have done for 3 years and my tsh hovers around 2.5. I don't feel any different that I did when it was 22! I've had t3, t4 etc and all my results are fine.
I do think people are overestimating the percentage of those affected my conversion probs etc. whilst I agree with posters who have found this as their problem, it's not the norm and not that common when compared to the number of people who are hypo. The majority (as op said) probably have underlying issues if they are having symptoms once medicated.
For example I have thinning hair but equally so does mum and nan who are not hypo so my endocrinologist says it's likely genetic. I am tired but then I'm always anaemic. In fact it's iron tablets that make me better more than anything. When my tsh rose years ago from 1.2 to 2.5 I asked the doctor to increase my meds and he said no. He said my levels were all fine and it must be something else.
It turned out my ferretin was 10 - (range 12-300!!!). After 2 years of iron tablets i got my ferretin to 80 and I feel loads better. My hair is in the best condition it's ever been though still thinning. I'm also deficient in zinc, vit d etc so all likely causes of thyroid symptoms.
For those concerned about pregnancy, my tsh was always around 3 when pregnant and I was never tested during the pregnany or took more thyroxine, had no issues at all. Given most gps use the range 0.5-4.5 for tsh, literally thousands of women are having pregnancies at these levels as most GPS are happy with tsh in this range. Thus, even if 2 is optimal, most women are probably having normal pregnancies at higher levels than this - lots of threads on here make it sound scarier if levels are not under this magic 2 number.
Also my friend takes a lot of thyroxine and her tsh is 0.3 but she feels dreadful on a reduced dose, but quite simply, it's bad for her heart and I totally get why the doctor rules she must reduce. It's surely about weighing up the risks.
I don't doubt there lots of bad practice with treating thyroid but I don't believe this failure with tsh monitoring affects as many people as these threads suggest - failure of conversion etc seems to be suggested to everyone who doesn't feel better on tsh.
Loads of things cause thyroid symptoms.