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Some of the big plot changes made in the remake: 1. It is not actually mentioned, only implied that the family members are cannibals. A well-known set piece of the TCM movies was the dinner scene in the original in which the family tries to eat their victims. 2. The whole family has changed. Now there are 7 members of the family, and the "grandpa" from the first four movies is not included here.
A then-unknown John Larroquette provided the narration in the original The Texas Chain Saw Massacre (1974). Despite becoming a distinguished actor in the years since, he happily agreed to reprise his role for the remake.
During the scene in the van with R. Lee Ermey (The Sheriff) and Jonathan Tucker (Morgan), Tucker forced the gun down his throat in order to make himself vomit every take. If you watch carefully you can see him spit the vomit out of his mouth in the scene.
Erica Leerhsen screamed so loudly during her screen test that people in other parts of the building called the police to report that a woman was being attacked.
After learning about the remake, Andrew Bryniarski (Leatherface) went up to producer Michael Bay at a Christmas party and personally asked him for the role.
While filming the scene with the possum, the filmmakers had to reshoot the scene numerous times in order to deliver the scares but everytime they filmed it, the possum appeared more adorable than scary.