Walter Hill and David Giler both collaborated on a script that was ready for filming in 1990 with Hill slated to direct, but the project was then put into turn around and Hill eventually dropped out of the project altogether soon after.
Harrison Ford damaged some ligaments in his leg during the filming of the scenes in the woods. He refused to take surgery until the end of filming so that his character would keep the limp. The limp can be seen in any subsequent scene where Richard Kimble is running.
According to producer Roy Huggins, Gerard's line in response to Richard Kimble's claim of innocence ("I didn't kill my wife") was originally read in the script as, "That isn't my problem." But at the request of Tommy Lee Jones, it was changed to, "I don't care."
Kimble's apartment is modeled after an actual doctor that Harrison Ford and Andrew Davis met in a Chicago bar shortly before filming. Ford felt that the doctor, somewhat eccentric and reclusive, was exactly how he wanted to portray Kimble and sent the art department to see his apartment. The doctor was also treated to a drink by Ford.
The train scenes were filmed in Dillsboro, North Carolina. The engine used (which was not destroyed) now pulls a dinner train. During a ride on that train, props from the making of the film can be seen, including the prison bus and the shell of the engine that crashed into the bus. Dillsboro is next to the town of Sylva, where the local hospital was used for filming the hospital scenes in the beginning of the film and the ambulance get-away.
Originally Julianne Moore's character had a bigger role in the film even after she exposes him briefly. Kimble was to have sought her out for help and eventually fall for her. These scenes were filmed and deleted from the final cut of the film. That is, however, at the same time her name is still credited as one of the main stars of the picture.
Harrison Ford was the first actor to sign on the the film in September 1992 and personally agreed with Andrew Davis directing the film after seeing Under Siege (1992), and being very impressed with the results.
The scene where Kimble is running through the St.Patrick's Day parade was not scripted. This was a later addition by Andrew Davis. Davis who is a native of the city, really wanted to capture the parade and was granted permission from the mayor's office to film the day of the parade. All shot with a hand held steady cam.
The character of Cosmo Renfro was supposed to die in the finale of the film. However, Joe Pantoliano successfully lobbied for his character to be spared so that he may appear in a potential sequel. Pantoliano indeed got to reprise the role of Renfro in the sequel U.S. Marshals (1998).
Richard Kimble was played by David Janssen in the original TV series The Fugitive (1963). His mother, Berniece Janssen, is an extra in the courtroom scene. You can spot her behind Harrison Ford's head while they play the 911 call and when he is declared guilty. She is whispering with another woman.
To date the only remake of a regular television series to be nominated for a Best Picture Academy Award. Earlier winner Marty (1955) was a remake of a television movie of the week. Later nominee Traffic (2000) was adapted from a television miniseries.
The picture of Richard Kimble on the composite from medical school is actually Harrison Ford's yearbook picture from Ripon College. He (almost) graduated in 1964, nine years before the picture was said to have been from.
During the St. Patrick's Day Parade, the smiling African American man in the hat is Roland Burris, then Attorney General of Illinois, and later became the Junior Senator from Illinois who filled the seat vacated by President Barack Obama.
Kimble tells Girard he is in St. Louis, on the phone at an El station. When Renfro is discussing the El train with Sam Gerard and colleagues, he states that St. Louis doesn't have an El. This movie was released one week after St. Louis' light rail system, the MetroLink, first began operation.
Andrew Davis only had one chance to crash the train in the train scene and had to get it right, so he consulted an array of engineers, stunt doubles, the insurance company, to try to ascertain exactly what would happen. The train was expected to crash into his bus at a speed of 35 miles per hour, but the director was in error. The train came at a speed of 42 miles per hour. Nevertheless, the scene still went exactly as planned.
A destination indicator on an EL train reads "Kimball" and the next shot tracks over a building that has a sign reading "Harrison" (These are two actual Chicago locations; in addition, there are both subway and EL stops on a Harrison Street).
The young boy Kimble treats at Cook County Hospital is played by Joel Robinson. His real name is used in the film, as Kimble refers to him as "Joel," and his full name can briefly be seen when Kimble inspects his chart.
Dr. Kathy Waylund (played by Jane Lynch) was considered as a love interest for Richard Kimble during production. However, their relation remained platonic, as it would have looked bad for Dr. Kimble to take a new lover while avenging the death of his wife. In addition, it was thought the love scenes would have added considerable length to the film and may have ruined the pacing and tension of the story at that juncture.
Richard Jordan, who was originally cast as Dr. Nichols, actually filmed some scenes with Harrison Ford before he became ill and had to drop out of the picture. These scenes had to be re-shot with Jeroen Krabbé. If you look closely at Krabbé's first scene, Ford's beard looks different because he had to regrow it for the re-shoot.
During flashbacks to the fund raiser early in the film, a sign for the pharmaceutical company Devlin McGregor mentions their work in pediatric care. In the original The Fugitive (1963), Dr. Kimble had been a pediatrician.
The studio and the producers of the film were extremely happy with Andrew Davis' cut of the film, (this was before he finally edited it down to its final running time of two hours and eleven minutes) and told him "It's perfect, don't touch a thing", then Davis made another 1600 edits to the film for pacing and tightening up scenes that needed to be stronger.
Director Andrew Davis shot a lot of material during production. With a tight deadline between filming - editing - and release, six editors were hired to quickly assemble all the footage that was shot. To speed up the process, Andrew Davis and his team used an AVID editing machine to piece together the film. There were two machines used with three editors at each one, under the supervision of Davis.
Before filming began and work was continuing on the script, Andrew Davis consulted his sister (who happens to be a doctor) as to what Kimble would do to get himself sent to jail. Her answer was a drug protocol. This was the essential part of the plot that is revealed briefly during the opening sequences prior to the murder of Helen Kimble (Sela Ward), as Ford meets one of the pharmaceutical moguls (MacGregor) involved with the project. Devlin the other mogul involved is only seen in photographs. This is finally brought to light once Kimble discovers the identity of the One Armed Man and eventually to his friend.
Just before Nichols attempts to open fire on Gerard, Richard assaults Nichols with a metal pipe and saves Gerard's life in the process. Such is the polar opposite of the series finale of the original television series "The Fugitive." In the final episode, Kimble and the one armed man (the only villain responsible for Helen Kimble's death) were fighting in an amusement park. The One-armed man pointed a pistol at Richard only to be gunned down by Gerard just before firing. However, Richard Kimble saved Gerard's life multiple times throughout the series before Gerard repaid the favor.
When Kimble calls Nichols to tell him that Devlin-McGregor is behind his wife's murder, Kimble is phoning from the lobby of the University of Chicago's science library (John Crerar Library). Crerar is known for its extensive biomedical texts collection.