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Alec Baldwin was first choice to play Dr. Richard Kimble. When he dropped out, Andy Garcia was considered for the role, but later worked with Andrew Davis on "Steal Big Steal Little" (1995). Harrison Ford had previously played a role that was first offered to Baldwin, in Patriot Games (1992), which happened to be the role of Jack Ryan. This character was played by Baldwin in The Hunt for Red October (1990), which incidentally, marked the first big screen appearance of Jack Ryan.
Harrison Ford damaged some ligaments in his leg during the filming of the scenes in the woods. He refused to take surgery until the end of filming so that his character would keep the limp. The limp can be seen in any subsequent scene where Richard Kimble is running.
The scene where Kimble is running through the St. Patrick's Day parade was not scripted. This was a later addition by Andrew Davis. Davis, a native of the city, really wanted to capture the parade and was granted permission from the mayor's office to film the day of the parade. The entire sequence was shot with a hand-held steady cam. Without rehearsal, Ford and Jones just went out into the crowd and did their thing, with camera operators running around trying to keep up. Ford observed that since his character was keeping a low profile, it meant he himself didn't stand out much and lasted several minutes in the crowd before being recognized.
Andrew Davis only had one chance to crash the train in the train scene and had to get it right, so he consulted an array of engineers, stunt doubles and the insurance company to predict what would happen. The train was expected to crash into the bus at 35 miles per hour, but the director was in error - the train came at 42 miles per hour. Nevertheless, the scene went exactly as planned.
Originally, Julianne Moore's character had a bigger role in the film, even after she exposes him briefly. Kimble was to have sought her out for help and eventually fall for her. These scenes were filmed and deleted from the final cut of the film. This is the reason that her name is still credited as one of the main stars of the picture.
The wrecked train and bus remain a tourist attraction in Dillsboro, North Carolina.