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At the 2007 Power Morphicon, actor Austin St. John admitted he originally had an idea for an alternate entrance for Jason when he is turned evil upon being sacrificed in Maligore's temple. Instead of snapping his chains, Jason was to flip off the edge of the pit, land behind Tommy the Red Turbo Ranger (played by Jason David Frank), wrap the chains around Tommy's neck and flip him over his shoulders to the ground. Jason would then use the chains to wrap around Tommy's throat and try to strangle him until Tommy breaks free. Co-director Shuki Levy ultimately talked the actor out of putting the idea in the movie, feeling the sequence was too dark for a children's film and would make Jason seem too evil to his fans if he tried to murder his old friend Tommy.
The first cut had a running time of 3 hours. To this day, none of the deleted footage has surfaced.
Amy Jo Johnson made her last appearance, on "Power Rangers" as Kimberly Ann Hart in this film, although she did return to the franchise for a cameo in Power Rangers (2017). Johnson appeared in "Turbo" because she was contracted to appear in two Power Rangers movies.
In the film, Kimberly is captured by the Malachians on the island of Muranthias and tied to a wooden slab. Amy Jo Johnson made a point of reminding the actors who were playing the Malachians who were carrying her to keep her safely away from the pyrotechnic effects on the set of Maligore's temple, because she had a traumatic experience with pyrotechnics early in her Power Ranger career. In Switching Places (1993), where Kimberly and Billy (David Yost) switch minds by accident from Billy's invention, a special effects accident had set both Amy Jo and David on fire.
Austin St. John and Amy Jo Johnson were originally considered by producers of the "Power Rangers" show to take over as the Red Turbo Ranger and Pink Turbo Ranger, respectively. Jason David Frank and Catherine Sutherland wanted to leave the show. Both actors declined to return to the show full-time due to the exhausting work hours of the show and wanting to act in other projects.
An original script had the Rangers encounter a new ally, Mandika the mermaid. She was described in the script as a girl with alabaster skin, blue and black hair that trails over her bare chest, a silver tail and she would have spoken with a strange voice. She would have already known Zordon and Alpha 5 and was sent to help them find the Ghost Galleon ship, as well as help out throughout the story. All of the scenes were apparently shot, but cut out of the final film.