Moustapha Akkad has said that one of his biggest regrets about the film was killing off the character of Rachel Carruthers. In retrospect, he would've kept her alive, but she was killed in an attempt to show that no one, not even Rachel, was safe from Michael.
(at around 32 mins) The bus that the Man in Black gets off of stops outside the exact same store where Jamie and Rachel went to get a Halloween costume in Halloween 4: The Return of Michael Myers (1988).
In the infamous laundry chute scene, Jamie was originally stabbed in the leg but the shot was cut from the film by the MPAA because it was deemed "too disturbing". Danielle Harris still owns the prosthetic leg.
When filming a scene, Donald Pleasence accidentally hit Don Shanks in the nose, breaking it. As a result, they had to cut out the nose of the mask and add on a paper thin nose cut off of another H5 mask. The edges of the nose appliance can be seen clearly in a lot of the film.
As part of the opening, an alternate scene was shot but never used. The scene shows a man who finds Michael Myers' body at the beginning and removes his mask, staring at it weirdly. The filming of it can be seen in the documentary, Inside 'Halloween 5' (2000).
Don Shanks revealed in an interview that many of the scenes involving the man in black had him playing the character, because of speculation that he was a blood relative of Michael Myers. He also admitted that even the writers had not yet decided the man in black's identity.
KNB Effects had designed grotesque facial makeup for Michael Myers' unmasking towards the end of the film. The producers told them to do so as an option, either showing Michael's badly scarred face or keep it in the dark. They went for the latter.
This film had one of lowest international theatrical distributions of the series, being seen only in Argentina, Colombia, France, Germany and Turkey. Elsewhere, it was released straight to video, with large campaigns in Norway, the UK and Spain.
The scene where Michael Myers drives a car while wearing a different kind of mask was initially scripted to have him wear a Ronald Reagan mask. However, the idea of a Reagan mask was soon rejected in order to keep the film devoid of any political subtexts.
(at around 7 mins) This is the first Halloween film to have Michael Myers with black hair. His original hair color is blonde. You can see Michael in this film without the mask twice, first when he wakes up in the cabin and again in the attic when he's in front of Jamie (at around 1h 27 mins). Tom Morga is one of two actors to have played Myers who had a different hair color. The other is Brad Loree in Halloween: Resurrection (2002).
The Jamie Lloyd character has a striking parallel to the Tommy Jarvis character from the Friday the 13th series. Both characters appeared in the fourth, fifth and sixth films of their respective series. They were both about the same age in their first appearance. They both become institutionalized and develop homicidal tendencies themselves after the killer. In this film, Jamie starts out as a mute. In the fifth Friday the 13th, Tommy rarely speaks. At the end of that film, Tommy is seen holding a knife and essentially becomes Jason. At the end of the previous Halloween, Jamie is seen holding a pair of scissors and she essentially becomes Michael.
The laundry chute scene was filmed with 30 different sections of the laundry chute. Some were full props, others were positioned horizontally to run the camera through on a dolly, and others were various sections that had cut-out portions for filming. Although the scene was very complex, it was all shot in one night.
In an odd coincidence, the fifth film of all three of the major slasher series (Michael, Freddy and Jason) has a different title in the film than the one shown on its cover. In this one, "The Revenge of Michael Myers" is missing. In Friday the 13th Part V: A New Beginning, the "Part V" is missing. And in A Nightmare on Elm Street 5: The Dream Child, the number "5" is missing.
On the DVD audio commentary, director Dominique Othenin-Girard stated actress Tamara Glynn (Sammie) became increasingly tense and 'unfeminine' as they got closer to filming the love scene between her and Matthew Walker (Spitz) in the barn. Glynn even asked co-star Danielle Harris to be on set during the filming of that scene to help ease her tension.
Tina was originally scripted to wear a devil costume to the Halloween party but this was changed so that Samantha wore this instead as Dominique Othenin-Girard did not want the heroine dressed like a devil.
In terms of his appearance, the Man In Black's wardrobe of a long, black coat and black cowboy boots, is a nod to country music singer Johnny Cash, who often wore long, black coats and black cowboy boots, thus earning him his famous nickname "The Man In Black".
In the script, Rachel had Tina's role, and Tina had Rachel's, with a vast change in character for Rachel. Also the script had a scene in the Myers' house that had The Shape fall through the floor into a cage in the basement, and the end had Michael escaping with Sheriff Meeker finding an empty cell, and other drafts had Meeker dying.
Donald Pleasence had disagreements with Akkad and Othenin-Girard citing that Jamie should have been portrayed as "all evil" after stabbing her stepmother, Akkad disagreed thinking that fans wanted to see more of the shape, in an interview Daniel Harris explained what she thought of the idea, "The way Halloween 4 ended I thought I was going to be the Killer, I thought it would have been fun to come back as the Killer or Michael sidekick. Scary, but fun".
This is the first time Michael Myers is shown driving since the original Halloween (1978). While it's obvious he drives a tow truck in Halloween 4 (right after Loomis confronts him the the garage/diner), you never actually see him behind the wheel.
1989 marks the only year entries from the three biggest slasher franchises of the decade (Friday the 13th, Nightmare on Elm Street, Halloween) were released in the same year; Friday the 13th Part VIII: Jason Takes Manhattan (1989), Nightmare on Elm Street 5: The Dream Child (1989), and Halloween 5: The Revenge of Michael Myers (1989).
The trivia items below may give away important plot points.
at around 1h 29 mins) In the scene where Michael is ambushed by Dr. Loomis and beaten with a 2x4, Don Shanks was really hit with the plank. He later admitted in an interview that one of the blows broke his nose.
In an article that appeared in the October 1989 issue of Fangoria magazine, director Dominique Othenin-Girard claimed that the film's ending was not scripted. Donald Pleasence stated in the same article that the film would contain the death of his character Dr. Sam Loomis.
The film had been fighting an X rating with the violence, blood, and gore. Some scenes were trimmed down to keep it rated R, including a shot of Mike quivering on the ground after Michael stabs him in the head with a hand rake, a shot of glass embedded in Officer Eddy's face after Michael punches through the windshield, and Billy's leg being hit by the Camaro, the scythe that kills Samantha was originally supposed to go through her forehead.
When Rachel's death scene was altered by the actress' request, it was changed in order to reflect the flashback where Jamie stabbed her foster mother in Halloween 4: The Return of Michael Myers (1988) in a similar fashion.