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To avoid an NC-17 rating in the USA, the more graphic shots of Morgan's death were cut. The original version of the scene featured the shot of the chainsaw slicing into his crotch and then having intestines and blood falling out of him. The cut version cuts away when the chainsaw is about to cut him and totally cuts out the intestines falling from his body. The hitchhiker death scene was also cut severely. The original scene has her ear flying off of her head and blood and brain matter being more dark in color and more in amount flying out of her head. Jedidiah was originally supposed to be killed by Leatherface for helping Erin and Morgan escape, but the scene was scrapped for being "too intense".
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.