Harrison Ford was adamant that he got to wield Indiana's famous whip. Paramount executives wanted the weapon to be computer generated because of new movie safety rules, but Ford branded the rule "ridiculous."
Harrison Ford convinced David Koepp to include more jokes about Indy's age in the script, believing they would help reduce the "American paranoia about aging." He also refused to dye his hair for the role, arguing Indy's appeal wasn't in his youth, but in his imagination and resourcefulness: "My ambition in action is to have the audience look straight in my face, and not the back of a stuntman's head. I hope to continue that, no matter how old I get."
When filming the scene where Indiana drives a truck through a wall, things did not go as planned. Timed explosives were used, but one explosive did not go off and landed in the seat next to Harrison Ford.
Harrison Ford had kept himself in such good shape over the years that his costume measurements for this movie had not changed from those in Indiana Jones und der letzte Kreuzzug (1989). He performed many of his own stunts, because stunt technology had become safer since 1989. He also felt it improved his performance.
Cate Blanchett and Harrison Ford had never met before this movie. The first time they were introduced was on the first day of filming, where Indiana and Spalko first meet. Blanchett said it was ideal to be introduced to him dressed as Indiana Jones, because she'd always been a big fan of the character.
Chet Hanks: The son of frequent Spielberg collaborator Tom Hanks plays one of the students in the library.
Steven Spielberg: [Fatherhood] Mutt's father wasn't around during his childhood. The diner where they talk is named Arnie's after Spielberg's father.