(at around 14 mins) Near the beginning of the film, when Castor Troy turns round and sees his brother Pollux Troy being pinned down by cops, the camera zooms in on Pollux's face as he shouts "CAS!". However judging by the lip movement and expression of Pollux, it's obvious that the word was dubbed over the video.
(at around 40 mins) The Geneva Convention regulates the treatment of victims and prisoners of war, not criminal prisoners of society. The guard saying that the Convention does not apply in the prison means nothing, it doesn't apply in any civilian prison.
(at around 1h 55 mins) In the shootout at the church, how could Sasha not realize that "Sean" is actually Castor when his gun was pointed at "his own wife" and his henchmen are not pointing their guns at him but at "Castor."
(at around 38 mins) Just before Sean (as Castor Troy) goes to Erewhon Prison, his friend Tito says there are 6 days until the 18th, when the bomb is supposed to go off. Just before that, though, there's a shot of the bomb that says there are 216 hours until it explodes. Tito could have meant six days after Sean got out of Erewhon, the bomb would go off, but Sean is supposed to be in Erewhon two days, which means the bomb would go off in a maximum of eight days. 216 hours, though, is nine days, not eight. That clarifies the meaning of what Tito said, but the time frame is still incorrect.
(at around 1h 11 mins) Just before Dubov gets shot by Walton, we see Burke Hicks running up to Walton to try to stop him. A few minutes later when Dubov falls down and Walton tries to shoot Castor, Burke Hicks runs up to Walton again.
(at around 2h 5 mins) In the last scene where Archer (as Castor) is fighting Castor (as Archer), Archer screams in pain when Castor hits him, but it's Castor's voice. In the previous scene, the microchip in his larynx was dislodged, so he spoke as Archer again.
(at around 34 mins) When Castor Troy (C. Troy) and Sean Archer (S. Archer) are having their faces switched in the laboratory, the monitor for Castor Troy shows his name as "T. Castor". When in fact it would read either "Troy. Castor" or "Troy. C". Hospitals/ Institutions always record patient details as: Surname. First Name / Initial.
During the hangar shootout one of Archer's federal agents is killed with a shotgun blast (we get a good look at his face), yet a few moments later you notice the same agent is standing, alive and well.
(at around 6 mins) Just after Castor Troy activates the bomb in the LA Covention Centre, he walks behind a choir girl, says something to her, then grabs her hair, in the first shot we see of them she has a bit of hair hanging down next to her ear, but in the next shot, Castor has all of her hair in his hand pulling it back from her face.
(at around 38 mins) At the Walsh Institute, after he gets the face transplant, Archer is told that the bomb is set to go off in 6 days; however, the subsequent shot of the bomb shows 216 hours (9 days) on its timer.
(at around 21 mins) After they receive Archer in the office with applause for catching Castor, he checks the computer for his son's file. It states he was murdered on Sept. 9th, 1991. However, later in the movie (at around 1h 14 mins), when they go to the cemetery on Michael's birthday, the grave states Sept. 24th, 1991.
When Castor Troy is captured at the beginning of the movie, he is clearly in possession of his famous twin 1911 gold-plated gun, yet later, when Archer goes to Dietrich's apartment, Dietrich gives him the same guns.
(at around 9 mins) On the plane at the beginning of the movie, Castor (still Cage) passes his drink to his left hand when the stewardess sits on his lap, however, a second later he's putting a cigarette to his lips with his left hand, and the drink is back in his right.
(at around 44 mins) When Archer (as Troy) is fighting with Dubov in prison, he hits him several times with the metal tray. Before Archer hits Dubov, he is hitting him like a left-handed baseball player, but after impact the camera switches angles and he continues through the hit as a right-handed baseball player.
(at around 2 mins) In the beginning of the movie, Sean Archer is sitting on the merry-go-round with his son, Michael, and the bullet goes through Sean's chest and into Michael's head, shown by the amount of blood that seems to be dripping from Michael's forehead. Later in the movie (at around 21 mins), though, a summary of Michael's death shows that the bullet was through his chest, not his head.
(at around 12 mins) After Sean Archer gets into the helicopter to chase Castor Troy, Castor fires three times from the plane at the helicopter. In the next shot there are four bullet holes in the windscreen.
(at around 1h 11 mins) When Dubov falls over the hand rail after getting shot, Archer (as Castor) holds onto the barrel of the gun and his hand is slipping. His hand clearly changes position on the barrel between different camera angles.
On the runway, when Castor arrives in his car, he is wearing three gold rings - one on his right hand (ring finger) and two on his left (pinky and middle finger.) In the plane, a clear shot of one of his hands shows that he is wearing a ring on his pinky only. Whichever hand this is, right or left, it is inconsistent with the previous scene.
(at around 1h 35 mins) When Pollux falls through the skylight, we can see glass shattering but in the shot where Troy (as Archer) is shielding himself from the glass, all we see is Pollux's body falling and no glass.
(at around 2h 5 mins) In the boat chase scene, we see Troy (as Archer) take a swing at Archer's face (as Troy) with the anchor, miss, and leave a hole in the boat. In the next shot, the part of the boat where there is supposed to be a hole, is perfectly smooth.
(at around 20 mins) When Sean Archer is holding the bottle from the CIA, he holds it at the base of the bottle in the quick shot while he is walking around his secretary but in the closeup shot of him putting the bottle down, he is holding it at the top.
(at around 2h 10 mins) When Archer and Castor are lying in the stretchers after Castor has been killed, there is a lot of blood on the collar of each of their shirts. in the next scene the blood pattern changes so there is almost no blood, but in the scene immediately after, the blood returns. This is evidence that the shirts were changed during the filming.
(at around 1h 9 mins) During Archer's escape from Erewhon, the computer screen that flashes Castor Troy and Dubov's names also displays Pollux Troy's name in the same list. However, Pollux Troy had already been released and is no longer an inmate at Erewhon.
(at around 1h 11 mins) When Dubov falls over the hand rail after getting shot, he initially falls backwards. Then when the scene cuts, before he is caught by Archer (as Castor), he's falling over the hand rail forwards.
(at around 1h 30 mins) When the swat team begins shooting into Dietrich Hassler's apartment, Archer grabs Sasha and her son, and jump behind the bed. Dietrich is then seen sitting on a couch, as Dietrich stands and begins to walk, a camera can clearly be seen rising behind and to the left of him.
(at around 1h 1 min) Immediately after the motorcycle cop pulls up during the Convention Center evacuation montage there is a wide shot of the frenzied street; in the background a camera crane with camera and operators is visible as it tracks upward.
(at around 12 mins) During aircraft chase scene at beginning of the movie, Castor Troy is steering the jet with the yoke while plane is on the ground. Aircrafts are steered by the rudder pedals while on the ground.
(at around 1h 35 mins) Near the end of the raid on Dietrich's place, Loomis busts in armed with a , with an underslung M203 Grenade Launcher. He fires the launcher twice in rapid succession. The M203 is a one-shot launcher and requires reloading between shots. There is no indication that Loomis bothered to reload at all.
(at around 37 mins) After the face surgery, Archer (as Troy) says his voice still sounds the same. Dr. Walsh tells Archer that he's implanted a micro-chip on his larynx, so he'll have to be careful because pressure, a sharp blow, even a violent sneeze would dislodge it. If this was the case, the micro-chip would have easily been dislodged in first prison brawl between Dubov and him (at around 42 mins).
(at around 1h 50 mins) In the funeral scene, the flag draping the casket is lying in an incorrect orientation. It is conventional for the union of a United States flag to be at the head and on the left side of the body, covering the heart.
At the end of the movie when Archer adopts Adam and brings him to his home, Eve looks very surprised. It is very likely that California state law would require written consent from both parents for adoption.
(at around 1h 45 mins) In Troy's blood test results the word "hematocrit" (or "haematocrit") is misspelled as "hemotocrit". Besides, some numbers (such as the white blood cell count or its reference range) are clearly made up.
(at around 1h 35 mins) During the raid on Dietrich's apartment, Archer (as Castor) grabs a FBI SWAT member and says "Buzz" as he remembers him, however at that exact point, Dietrich is seen behind Archer's right shoulder. Archer makes out that he "killed" the SWAT member, but Dietrich saw Archer compromise his cover and then fire one round into the floor.
When Castor sets the bomb it is set for 236 hours (just about 10 days) after the initial surgery, there is a shot of the bomb indicating it was about 216 hours. There is no way that the surgery and subsequent healing process, in addition to the chase, capture, interrogation, etc. that took place in such a short interim.
(at around 53 mins) The choking that Archer gave Troy during the visitation scene should have been more than enough to dislodge the microchip in his larynx, therefore preventing him from talking in Archer's voice for the remainder of the film.
(at around 46 mins) When Castor awakes from coma, he starts taking off the bandage. He's not supposed to have skin on his face, but in one shot, he still has it on forehead and on the left side of his face.
(at around 17 mins) Obvious stunt double when Castor Troy is thrown against the fence (and knocked out) when he is thrown behind the jet engine during the airplane hangar sequence during the beginning of the movie.
(at around 1h 40 mins) After Pollux falls through the skylight, Troy (as Archer) is visibly upset. When Loomis enters the room, you can clearly see the "bullet hole" covered up on his forehead; it is also visible when he says "It's just Pollux Troy" and Troy shoots him in the head, exactly where the makeup-covered mark is. You can see it explode with the impact of the shot.
(at around 56 mins) When Castor as Archer reads Eve's journal the latest date reads the 17th which would put it the day before the bomb at the convention center was to explode. But as he reads it, the text states the Archer had come home after catching Castor and told her that he had to go back on assignment. The events described would actually have happened on the 7th, according to the movie's time line.
The helicopter broke off the Aileron instead of the Horizontal Stabilizer (Pitch Control). The jet still can take off with broken aileron but not advise to do so since it is dangerous in the air. The aileron control the turning but the experienced pilot can control the yaw with left and right engine power output.