Today I replaced the pan/filter and some fluid on my car at 61,000 mi. with a kit from Cali Trans. I suspected this was the first filter/fluid change on this vehicle, as the PO was not very conscientious about maintenance. For those of you who have performed this procedure yourselves, can you remark on the following?

1. When removing the fill plug, oil gushed out. At least 1L. How is it possible that this much fluid was above the fill hole?
2. New Lifeguard 6 fluid has an extremely noxious odor. The old oil had none. Explanation? Maybe somebody replaced the OE oil previously with another product? The old oil was light brown, not red like any other ATF I've seen.
3. Following the ZF instructional video exactly, I was able to replace only 3L of oil. I did need to add about 1/2L after initial fill, per instructions. Is 3L typical?

I've sent a sample to Blackstone, maybe they can identify the manufacturer as well as analyze.

 

Not sure how you performed the service but it's tricky!
The level must be checked while the car is running and the transmission fluid temperature is at a certain temperature. You did not say how you checked the fluid level? If done properly using the side plug then yes it was overfilled. Since you have the 6 speed ZF you can use Mercon SP which is identical and is red unlike the Lifeguard6 which as you noted is a light brown color.

You should drop and replace the integrated pan/filter assembly and then you should get between 6-7L of fluid out. Yes sometimes you do need to top up the fluid but I have never had too yet.
But with only changing 3L I would get the pan and filter and do a more complete change. I have found that if left to drain over night I can get about another Liter of fluid out of the transmission.
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Should have watched the video twice!
Second fill takes place with the engine running

 

Hope you didn't hurt the tranny!!

 

No ill effects; I caught my mistake in time
The Blackstone analysis came back, with comments. I questioned the aroma of the new fluid (See OP question #2), and their answer is satisfactory.
It appears that if you don't drive the car hard or do a lot of manual shifting, the oil may indeed be good for "life". Still, particularly if you have access to a lift, the job is DIY and a couple of hundred bucks. Cheap insurance.