In February 2011, the actors flew to Malaysia, where a few scenes were shot inside the Malacca Prison with real prisoners. A complete section of the prison block was made available for the shoot. In order to avoid any hitches, special crew T-shirts were made to differentiate crew-members from the prisoners as it was a high security zone.
Shah Rukh Khan will be performing his own stunts in Don 2. For this Shah Rukh needs to recover from this year's back surgery. This is why he allotted dates in 2009 to Karan Johar's My Name Is Khan (2010). It required very little physical exertion whereas in Don 2 he has a very audacious action packed role.
As Farhan Akhtar prepares to shoot for Don 2, he has said that his father 'Javed Akhtar' will be no part of this sequel to Don (2006). The first part of the film had been written by Javed Akter. Don 2 has a different team of writers which includes Farhan.
A car chasing sequence in the film used 67 cars specially shipped from Korea, and shut down some important streets in Berlin for three weeks, including the Brandenburg Gate. Every day, alternate routes and diversions were provided in lieu of the roads that were cordoned off for the shoot.
About Don 2 Farhan Akhtar says "The first film was my father's vision. He had written the original Don, along Salim, featuring Amitabh Bachchan. But Don 2 is being written by fans only. These are yours truly and two new enthusiastic boys Ameet and Amreesh who came to me with their ideas on how the story can be carried forward. I've thrown my ideas at them. Don 2 is basically being written by three Don fans who are having a ball carrying the story forward." About the exclusion of his father Farhan explains, "He cannot be a fan of Don because he conceived it."
During a chase scene Shah Rukh Khan said to his co-star Alyy Khan that he never crashed a car in an accident, while in next shot he accidently smash car with camera during the scene. He quickly apologize to the action team and humbly ensures them to recover the cost of damages
Shah Rukh Khan who plays the role of "Don", uses a dialogue while making a bargain with Detective Malik - "Make me an offer I can't refuse". This is a direct modification of the famous dialogue "I'll make him an offer he can't refuse" by Marlon Brando in The Godfather movie. Marlon Brando played the role of "Don" Vito Corleone in that movie.