If you read the entire post, it will be clear(?) that he had only looked at threshold voltage until I told him to look at the Rds(on) spec'ed voltage. He did, and was relieved to find that it was 4.5V.He said he looked at the "off" threshold voltage.
An IRL540 has a threshold voltage of 1V to 2V when it is almost turned off with a current of only 0.25mA. Its is spec'd to be turned on very well with a max on-resistance of only 0.058 ohms when its gate voltage is 5.0V.
At least, that's my take.
Chris? You can clarify this.