Aishwarya Rai Bachchan was originally cast in the role of Jwala, but dropped out in the last minute because of contract problems. Ameesha Patel was given her role.
When Kiron Kher was first approached for the part of Noor Bibi, she turned it down for various reasons. The makers then signed on Maya Krishna Rao for the role and they shot the scenes with her. However, director Ketan Mehta and actor Aamir Khan were not happy with the scenes and performance, so they approached Kiron Kher again who then agreed to do the film.
As part of a publicity campaign, the dairy company AMUL made several posters showing their trademark little girl dressed up in a Sepoy uniform and sporting long fake mustaches. They gave the name "MAKHAN AAN DE: THE SLICING."
After Aishwarya Rai Bachchan turned down the part of Jwala, Rani Mukerji was given the script to read and consider taking over for the part of Jwala. However Rani liked the character of Heera so much that she asked if she could play her instead. The part was much smaller at the time, but changes were made to the script to give her character more storyline.
During the shooting, when the crew was bored, Aamir Khan used to entertain them on the microphone by performing, especially "Aati Kya Khandala" and his popular TV commercial in which he played a Nepali guide.