I had total T too...so I have to keep my TSH suppressed too.
Okay...taking wild stab here:
Maybe your meds were sub-potent...or you had some sort of absorption hinderence. Or...perhaps you forgot to take meds? Perhaps you didn't really hit the sweet spot when you thought you had...and still needed more meds for suppression..?
The thing we all worry about is that the gland starts growing back. That would be cause for major freaking out.
I hope you get this straightened out