Deleted Role: Terry Crews played Jericho, a resistance soldier and brother to Barnes, in a deleted scene which never was included. Similarly, Greg Plitt's brief role as a hybrid similar to Marcus was deleted after a general plot change.
"The future is not set. Iíve been told I said that once. Many years from now. It was a warning. That I was going to hell. But if I fought hard enough, I could escape. I believed it for a lifetime. Now I pray I was wrong. Because now I am in hell. We all are. And the future I used to dread is the only hope I have left."
The original cut of the film included a topless scene when Blair and Marcus are warming themselves by the fire. Director McG said that it was meant as a Shout-Out to Kelly McGillis' topless scene in Witness, but that it ultimately felt exploitative and would have flouted a PG-13 rating. The scene is reinstated in the director's cut Blu-ray.
A longer third act, that had John and Kate having a longer conversation before he leaves on the mission to rescue Kyle, appearances by T-700's, more footage of Marcus infiltrating Skynet, prisoners escaping during the attack, the T-800 trying to use the T-600's minigun and Kyle burying Marcus and finding Sarah's Polaroid in John's jacket.
Franchise Killer: The plans for any future endeavors with this incarnation vanished at some point and prompted another reboot that reset the Terminator playing field altogether; Bale was not invited back, but Schwarzenegger was.
In an early script, Marcus was much more emotional and talkative, as well as Kyle and a non-mute Star, and they would encounter cannibals in the road and not a good-natured clan of survivors. Marcus would be revealed to be a brain in a fully cyber body, just like Serena Kogan, who would reveal Skynet was creating hybrids like them to build a new, superior human society as part of what they called Project Angel. John Connor himself wouldn't appear personally until the last act, and more shockingly, he would be killed by Serena while rescuing Kyle and Marcus would assume his role by surgical methods to lead the resistance.
Even after turning John into a main character (by Bale's demand) and adding the Ashdown subplot, the main plot points were kept when they started shooting. Helena Bonham Carter originally played the cyborg Kogan and not her image used by Skynet in the scene with Marcus, where he would have to face a T-800 as well, and John's death and impersonation by Marcus was going to be the official ending. However, this ending was blasted by everyone who heard about it after an internet leaking, with McGs himself finding it thoroughly wrong upon reading it, while the Project Angel storyline was felt as too derivative and out-of-character for the franchise, so they changed plans mid-production. Still, some scenes from these earlier ideas were shot and are contained in the DVD.
Stan Winston was intended to have a cameo as a prisoner who was fighting a Hydrobot in the Skynet research facility, but this was scrapped due to Winston's worsening health.
The submarine commanded by Ashdown was originally going to be destroyed by an underwater Harvester and not by a simple missile.
Had Arnold Schwarzenegger not given permission for his likeness to be used for the T-800 that attacks John Connor in the factory, the plan was to have Connor shoot the T-800's face off as the camera panned up.