At the end of the first movie when Chucky is burnt, his left eye is there and his right is melted shut. But at the beginning of this movie, when they are cleaning him, his left eye is gone and his right eye is opened and there.
The production of the new dolls seem to be mixed up. The new dolls have their hair attached to their heads and they didn't have their clothes on. But there was a shot of the dolls going through the machine and they come out with clothes on but they didn't have their hair attached yet.
After fostering Andy, as they drive along talking about what Andy likes to eat, in one shot Phil turns the steering wheel, and the car starts to turn a bend, but in the next shot they are driving straight, down a road.
Mattson tosses Chucky into the back seat of the car feat-first. In the next shot, Chucky is turned around, as if he was chucked in head-first. In the next shot when Mattson gets in the car, Chucky can be seen in the back seat turned around again as if he was chucked in feet-first.
When Andy is in the basement, he walks backward into the wash-dryer, and we see a big sheet hanging up on a line behind him, with five pegs. After he hears a noise and turns to look, now only four pegs hold it up.
The ring on the ring finger of Kyle's right hand disappears when she flips Chucky off before he enters the doll part insertion machine. In the next shot where her right hand is visible, the ring is back on.
In the factory, the first shot of the eye machine shows a doll getting eyes and hair attached with all the other dolls being hairless. Right after this, all of the dolls suddenly have their hair already and the machine adds eyes only.
When Joanne is reading a bedtime story to Andy during the stormy night, she mistakenly changes her accent to her native English accent. She even makes a change in her facial expression making her realize of her mistake.
When Chucky is being reconstructed and when the other dolls are made, you an see their legs are hard plastic or rubber, like a G.I. Joe action figure. However various times throughout the movie, when the doll is moved, its legs hang limp and swing like a rag doll.
Chucky's doll materials are not consistent. He is shown being made of plastic and his eyes are glass and movable, but when he is grabbed at some points in the point, his face is rubber, eyes painted on, and his "plastic" torso that was built in the beginning of the film is cotton.
In the previous film it is stated that Chucky was turning human and had a human heart. In this film the Play Pals employee tells the CEO that they checked out the remains of the burned doll and didn't find anything unusual about it at all.
When the toy makers are building the Chucky doll, they screw the battery cover onto Chucky. Later, when Andy inspects what he believes to be the Tommy doll, the battery cover does not have screws. If you watch in the beginning, when they actually put the batteries in Chucky, it is a plastic clasp door without screws. The screwed plate is seen above the battery chamber and is most likely the Good Guy doll's voice cassette, most likely screwed shut so children could not tamper with it.
After Chucky discovers he is trapped inside the doll's body he blames Andy for avoiding him but even if Chucky had managed to perform the chant in Andy's bedroom or the classroom as well as the basement the chant still wouldn't work as Chucky had spent 2 years in the same doll's body that got destroyed in the previous film. Had Chucky's soul been transfered to another Good-Guy doll as it was the case in the next film Chucky would presumably had been more successful.
There is no logical reason given as to why the Play Pals toy company wanted to spend time and effort restoring and reconstructing the charred Good Guys doll that Charles Lee Ray possessed in the previous movie.
When Andy opens the tap to the boiling, melted liquid plastic, some of the liquid squirts on his hand. The liquid is at boiling temperature and would burn him severely, but he doesn't notice, obviously because it isn't really boiling.
Many times in the film, it's obvious that Chucky is inactive and not alive, yet supposed to be. When he falls to the floor beside the photocopier, for instance, it's obvious he is off and inactive and just a "doll."
During a commercial in the first film the Good Guy dolls appear at least partially animatronic. At the very least the head rotates, and the eyes and mouth move. However in the beginning, as the Chucky is being rebuilt, he appears somewhat less sophisticated. Being almost entirely plastic, and hard rubber.
When Andy arrives at the Simpson house for the first time Phil tells Joanne he has to go back to work in the afternoon but the time on the living room clock is quarter to 5 meaning it is actually evening.
In the beginning of the movie when they are putting Chucky together, you see one of the Play Pals employees air brushing the freckles and eyebrows on Chucky's face but he didn't paint the eye lashes, he missed completely. Later on in the movie, you see that Chucky does in fact have those painted eye lashes even though they were never painted on.
The goof items below may give away important plot points.
When Grace Poole descends the stairs the boots she is wearing are deep black and glossy. Moments later when she has been stabbed and collapses in front of the photocopier the stunt woman playing her is wearing boots which are matte and lighter in tone.
In the scene where the security guard has to fix the machine that puts eyes in the dolls, after doll eyes are shoved in his head, you can clearly see his eyelids are closed and painted red. Plus, the eyes are mismatched. The left one is up a little higher than the right, even though the clamp held the guard's head perfectly in place.