The Other Darrin: Divatox. She was portrayed by Hilary Shepard Turner in The Movie, but while she was on maternity leave, she was subsequently replaced by Carol Hoyt in the television series for the first half of the series. During the second half of the season, Turner reprised her role, continuing well enough into Power Rangers in Space.
The change in actresses between the film and the show also brought about a change in costume and personality. Divatox's costume in the film was much more revealing and exposed a lot of cleavage, while her costume in the show was a little more covered up. Hoyt's Divatox was more calculating and evil while Turner portrayed Divatox as more of a hysterical diva.
Promoted Fanboy: Blake Foster was a huge fan of the show and was absolutely thrilled when he was offered the part of the Blue Ranger. Even at Power Morphicon in 2010, he said that being a Power Ranger was every kid's dream and that he kept his helmet and costume.
Romance on the Set: Between Johnny Young Bosch (Adam) and Tracy Lynn Cruz (Ashley). According to an interview with Bosch, she dumped him after getting cast as Ashley.
There were originally plans for Bulk and Skull to get their own Fawlty Towers-esque spin-off series, where they run a hotel with a Mexican Elvis Presley impersonator called "El Vez". This explains why both Paul Schrier and Jason Narvy left the series so that the producers could add chimpanzees to the show roster (with Schrier and Narvy still providing voices, though).
Somewhere exists a directors cut of the Turbo movie. Around forty minutes of footage cut from the final product...
The fifth revision of the script gave Justin a lot more motivation, explained the Turbo powers, explained why after they didn't pass the powers off to someone else. Oh sure, there are still some plot holes but it mostly patched them all up...
Originally only Jason David Frank was supposed to leave, having expressed interest in leaving since Zeo. Saban convinced him to stay through the first half of Turbo to let them write out his character properly, eventually during production of the first half of Turbo, they decided to get rid of all the veteran Rangers.
An unfilmed episode, titled "Rangers in Concert", originally planned to be the mid-season finale, was set to focus on a number of characters. This would have included: Carlos, whose surname was originally "Chavez"; Ashley, originally "Missy"; Lt. Stone's niece from "Cars Attack", Jenny Hunter (originally called "Ashley"); and Tanya's KAGV intern and clear T.J. prototype, Michael. Said episode was also to have the Blue Senturion show the first Turbo Rangers who would've fought Rockin' Roach - the full Millennium Message, allowing them to know who their replacements would be in "Passing the Torch".
Divatox was suppose to be revealed as Dimitria's twin sister see Aborted Arc on the main page.
The Phantom Ranger was meant to be revealed as a past Ranger such as Billy with his short appearances explained by having the first non-Zordon/man-made suit. Ecliptor would have been as a failed robot Ranger experiment of his.