In the film, Kimberly is captured by the Malachians on the island of Muranthias and tied to a wooden slab. Amy Jo Johnson made a point of reminding the actors who were playing the Malachians who were carrying her to keep her safely away from the pyrotechnic effects on the set of Maligore's temple, because she had a traumatic experience with pyrotechnics early in her Power Ranger career. In Mighty Morphin Power Rangers: Switching Places (1993), where Kimberly and Billy (David Yost) switch minds by accident from Billy's invention, a special effects accident had set both Amy Jo and David on fire.
Amy Jo Johnson made her last appearance, on "Power Rangers" as Kimberly Ann Hart in this film, although she did return to the franchise for a cameo in Power Rangers (2017). Johnson appeared in "Turbo" because she was contracted to appear in two Power Rangers movies.
Shuki Levy originally wanted Walter Jones to reprise his role as Zack Taylor. Jones declined when he learned he would have to give up his Screen Actor's Guild card to appear in the non-union cast for the movie.
Austin St. John and Amy Jo Johnson were originally considered by producers of the "Power Rangers" show to take over as the Red Turbo Ranger and Pink Turbo Ranger, respectively. Jason David Frank and Catherine Sutherland wanted to leave the show. Both actors declined to return to the show full-time due to the exhausting work hours of the show and wanting to act in other projects.
An original script had the Rangers encounter a new ally, Mandika the mermaid. She was described in the script as a girl with alabaster skin, blue and black hair that trails over her bare chest, a silver tail and she would have spoken with a strange voice. She would have already known Zordon and Alpha 5 and was sent to help them find the Ghost Galleon ship, as well as help out throughout the story. All of the scenes were apparently shot, but cut out of the final film.
The Turbo Zords were created by custom car builder George Barris. Barris had created custom vehicles for films such as the Stone Age cars in The Flintstones (1994), the spy cars for James Bond films, and the theme park terrain vehicles for Jurassic Park (1993).
Unlike the first movie, this movie takes place within the continuity of the television series. The first episode of Turbo takes place after the movie. Because of this, the design for the movie was closer to the television show. The Ranger suits were spandex rather than the armor-like suits of the first movie, and the Megazord was filmed with the series' suitmation style rather than computer animation. Also, certain sets and costumes from the movie, such as the Power Chamber set and the Alpha costume, were also used in the television series, albeit with no mention of the extensive makeover they received in the interim.
After Jason helps Kimberly escape the bilge of Divatox's craft, she was supposed to lose consciousness from lack of air and sink into the ocean. After Mandika the mermaid saves Bulk and Skull by giving them a log to use so they can swim to Muranthias, Mandika saves Kimberly from drowning and takes her to shore. The sequence and all footage of Mandika were cut, but the epilogue of remains, when native warriors find an exhausted Kimberly on the beach. This explains why Bulk and Skull aren't as tired as Kimberly when she arrives on the island.
In an original draft of the script, after Jason (Austin St. John) and Kimberly (Amy Jo Johnson) had been turned evil when they were sacrificed into Maligore's pit, it would have been revealed that they would have had enhanced strength as a result. This explains why they are able to fight the Turbo Rangers with ease and why Tommy is struggling when an evil Jason tries to strangle him. However, the scene with the explanation was cut due to the film's allowed running time.
On the Ghost Galleon ship, Nakia Burrise (Tanya) was supposed to hit one of the Putrapod monsters with a cannon. When she did, the cannon went overboard. The crew had to stop filming and retrieve the cannon.
During the sequence in Africa when Tommy saves Katherine, after he takes her to shore, Tommy was actually supposed to be attacked by a crocodile. He would have been dragged into the water by his Power Box backpack when the crocodile grabs it in its jaws, but he manages to jam a nearby log into the animal's mouth and swims to shore. When the crocodile follows Tommy to shore, Katherine takes a blow torch from her Power Box and fires a torch to scare the crocodile away. The sequence was ultimately cut to keep the running time of the film short. This is explains why there is a photo of Katherine holding a flame thrower on the back of the back cover of the movie's VHS and DVD, but it isn't seen in the film.
Rocky was originally was supposed to play as the Blue Turbo Ranger, but Steve Cardenas announced his departure to concentrate on his dojo, despite rumours he was injured after that while performing a stunt towards the end of Power Rangers Zeo (1996) and as a result had to leave the show, requiring the exit of his character. So while shooting the movie, he had to pretend he was not hurt and when he flipped, he would show his pain. The rumor was written into the movie.
Catherine Sutherland and Steve Cardenas originally signed contracts to stay on during Power Rangers. Miss Sutherland was to stay on as Kat and Mr. Cardenas was going to serve as a stuntman for the series. However, the two actors were ultimately let go from the series when the show eventually had four new Rangers accept the Turbo powers on the Power Rangers Turbo (1997) television series.
This movie marks a significant redesign of the interior of the Power Chamber from Power Rangers Zeo (1996). The Mighty Morphin' suit and weapons gallery has been removed and replaced with five Ranger-colored tubes, the console has been replaced with a larger one with two smaller consoles on either side and the floor design has also been changed.
The trivia items below may give away important plot points.
Shuki Levy originally wanted to bring back all of the five founding Power Rangers together for this movie: Austin St. John (Jason the first Red Ranger), Thuy Trang (Trini the first Yellow Ranger), Walter Jones (Zack the first Black Ranger), Amy Jo Johnson (Kimberly the first Pink Ranger), and David Yost (Billy the first Blue Ranger). Trang and Jones declined to return for the film, while David Yost quit working on the movie and the simultaneously-filming TV show Power Rangers Zeo (1996). Only St. John and Jo Johnson would agree to return.
In a video interview while at the 2007 Power Morphicon, actor Austin St. John confessed he had originally turned down reprising his role as Jason Lee Scott in the "Turbo" movie, but co-director Shuki Levy contacted the actor and tried to get him to re-consider. Mr. St. John read the script and liked it, but he agreed to return under two conditions. The first condition was that Mr. St. John wanted to get higher pay, which he was originally fired from the show for wanting, because he needed money to support himself and his mother. His second condition was that he wanted to turn Jason evil, because he felt it would be more fun playing the character as a bad guy. Mr. Levi agreed, but the two came to a compromise where Jason, as well as Kimberly (played by Amy Jo Johnson), would be turned evil only temporarily when they're sacrificed at Maligore's temple. Jason and Kimberly would be later turned good again by the wizard Lerigot. As a result of their meeting, Mr. St. John agreed to appear in the movie, he got a higher salary as requested, and the script was re-written to turn Jason and Kimberly temporarily evil in the film's third act.
An original shooting script for this movie was originally going to include a romance between former Power Rangers Jason Lee Scott (Austin St. John) and Kimberly Ann Hart (Amy Jo Johnson). This would serve as a possible reason why both Kimberly's unnamed boyfriend and Jason's girlfriend Emily from the TV series "Power Rangers Zeo" were not mentioned or present for the "Turbo" film, and explain why Kimberly congratulates Jason, not Tommy, in the finale when they win the karate match. However, while the romance was written out of the film, the concerned/loving glances between the two ex-Rangers remain present throughout the film.
The Zeo Rangers were supposed to appear in the film. According to Johnny Yong Bosch, the Zeo Rangers would lose their powers during a fight with Divatox's Piranhatrons and that is why the Rangers would upgrade to the Turbo powers in order to go to Muiranthias. The scenes were filmed, but the reason for their omission was not mentioned.
In the shooting script, Kimberly (Amy Jo Johnson) was supposed to cut her fingers while loosening the bolts to open the hatch in the bilge of Divatox's submarine. She quips "My manicurist is going to kill me." When Jason (Austin St. John) notices Kimberly's fingers are bleeding profusely, he tears off part of his tank top to cover her fingers and asks why she didn't tell him, to which Kimberly quips "I'm no weenie." The scene was cut out because Saban didn't want to feature too much blood in the movie, even though Kat (Catherine Sutherland) does get a bloody gash when she injures her leg at one point in the film.
At the 2007 Power Morphicon, actor Austin St. John admitted he originally had an idea for an alternate entrance for Jason when he is turned evil upon being sacrificed in Maligore's temple. Instead of snapping his chains, Jason was to flip off the edge of the pit, land behind Tommy the Red Turbo Ranger (played by Jason David Frank), wrap the chains around Tommy's neck and flip him over his shoulders to the ground. Jason would then use the chains to wrap around Tommy's throat and try to strangle him until Tommy breaks free. Co-director Shuki Levy ultimately talked the actor out of putting the idea in the movie, feeling the sequence was too dark for a children's film and would make Jason seem too evil to his fans if he tried to murder his old friend Tommy.
There was supposed to be a bungee stunt for Adam that Johnny Yong Bosch was excited about performing. Adam uses the bungee cord from his Power Box to save his new love interest Mandika the mermaid from one of Divatox's torpedoes while on the island of Muiranthias. The scene was filmed, but cut out because of the film's running time and because the character Mandika was cut from the film.
The crew originally intended to have the original Blue Ranger, Billy Cranston (played by David Yost), have a role in the film. Billy would have helped the Rangers create the Turbo powers in the original draft of the screenplay. However, Yost left Power Rangers Zeo (1996), which was filming at the same time as the Turbo movie, and the script had to be rewritten during production to exclude Billy. His character would leave during "Power Rangers Zeo" when his character is ageing due to exposure from a past experiment and has to go to planet Aquitar to regain his youth. Mr. Yost confirmed on his Twitter account that the rumours of him being spotted on set filming the "Turbo" movie were false.
In the movie, when a temporarily-evil Jason (Austin St. John) holds Tommy (Jason David Frank) by the throat over Maligore's volcanic pit, after telling Jason he's not using his brain power, Tommy was supposed to send Jason over with a kick to the groin and he stops Jason's fall into the pit by catching his foot. However, Tommy actually sends Jason over with a kick to the chest and Tommy stops his fall into the volcanic pit by grabbing his wrist.
This marks the final appearance of Ernie, as Richard Genelle leaves the "Power Rangers" series. Ernie can be seen in the crowd behind Kat, seated next to Kimberly, during the martial arts tournament in the finale. However, his character Ernie will not depart until the "Power Rangers Turbo" TV series when Lt. Stone mentions he has left the Juice Bar.