The only Disney-made season of the franchise where all of the main actors were all North American.
The first day of filming with the Doggie Cruger head nearly set John Tui on fire. Due to unfamiliarity with the equipment, someone put the battery in wrong and caused a short in the electronics which caused them to start smoking.
Creator Backlash: Bruce Kalish has gone on record to say that in hindsight, the treatment of Sam was not his finest moment.
"Abandoned" ends with a friendly alien saying "Maybe I'll go to New Zealand. No one will ever find me there!"
Piggy gets teleported there in another episode.
Doing It for the Art: Greg Aronowitz designed a lot of the alien makeup for background characters on his own time and dime.
Enforced Method Acting: In "History", the Dino Thunder cast was not allowed to see the Doggie Cruger suit until they actually started shooting scenes with him so that they really would be surprised by his appearance.
Executive Meddling: Disney wanted to save money and didn't want to hire a seventh starring actor, so it was written in that Sam the Omega Ranger, as a side effect of time traveling, was either stuck in his suit or transformed into a ball of light. This meant he was played on set by a stuntman in a bulky helmet and had his dialogue recorded later in ADR, making interaction between him and the other characters incredibly awkward. Apparently, the crew was so frustrated by this that they tended to write around Sam as often as possible; they probably would have written him out entirely if not for stock footage constraints. Additionally, Jason David Frank was not happy when he was not invited back for the team-up episodes as a cost-cutting measure.
The second Dino Thunder teamup episode "Wormhole" shares the same name with the first episode of the children's Sci-Fi show Black Hole High, which also used one-word episode titles. Coincidentally, both episodes were written by Bruce Kalish.
A number of alien extras have been seen using parts of previous monster costumes. One of the most noticeable was in "Dogged", where a guy on Gruumm's ship had Deviot's head.
The flashback with Cruger wielding a Spiral Saber and wearing a similar cloak to Andros's.
The monster on Sgt. Silverback's planet aka Silverback, testing the Rangers by using a hologram is actually Beetleborgs monster El Scorpio.
Hey look, a bunch of furry suits we've never seen come to help us along those we do know! Yeah, they'll be immediately recognized by Dekaranger viewers. Two of them were replaced by redesigns, the other two didn't make the cut.
The A-Squad's duty uniforms are the jumpsuits worn by the Dekarangers, which presents an odd contrast with the much fancier uniforms worn by the rest of SPD.
Piggy's cafe is a treasure trove of this. Monsters from Time Force, Lightspeed Rescue and other seasons, along with a Tenga and a gatekeeper from the MMPR movie (which, incidentally, executive producer Greg Aronowitz worked on). Even an unused GoGoFive (Lightspeed Rescue's sentai counterpart) monster made an appearance.
It Makes Sense in Context: Well the premise for this series was that Earth had become a haven for many extraterrestrials by this time, so many of the aliens in existence from Morphin' on being around is actually plausible.
The usage of In Space helmets for the A-Squad and Time Force suits back when Sky's father was a cadet.
Parsnippity is made up of different costumes such as Lost Galaxy's Deviot, In Space's Tankenstein, and the unused Timeranger monster Boribaru.
Troubled Production: Executive Meddling led to a good chunk of the series' budget being placed onto the series finale, which had a major CGI battle with the SWAT Megazord. However, this led to them being unable to do a number of things, including hiring an actor for Sam, the Omega Ranger. As well, many episodes were taken wholesale from itsSuper Sentai counterpart Tokusou Sentai Dekaranger. When Canada accidentally aired the second crossover episode between SPD and Dino Thunder, ABC held back that part for a good length of time before finally letting it air. Speaking of that episode, budget problems led to them to not even consider bringing back Jason David Frank who was back in the States. Frank has stated he was never asked to return. He was never seen out of his suit, and his voice was shemped by Trent's actor Jeffery Parazzo, as they couldn't afford to bring in a specially cast voice actor and Parazzo was already available.
Producer Greg Aronowitz planned for the season to have the first full-fledged female Red Ranger in the franchise's (including Sentai's) history, but since this is a series designed to sell toys to little boys, he was quickly shot down by higher ups from both sides of the Pacific. The idea eventually morphed into the A-Squad subplot.
A film that would take place after the series and would involve Jack rejoining the team was considered, but Disney rejected the idea. Ironically Toei would start a series of Super Sentai films for the 10th Anniversary of an series with Dekaranger being the second with basically the same plot concept.
A-Squad was going to be brainwashed, but there wasn't enough time to play out the concept, so instead we're stuck with the idea that all five of them apparently just woke up one day and decided to turn evil. The idea of them being brainwashed, however, was utilized in the Jetix Magazine tie-in comics.
Jack and Z were originally going to be brother and sister, sharing the last name of Manners before being casted apart.
You Look Familiar: Kelson Henderson, who appeared as a one-shot character in Dino Thunder, gets a regular role as not-quite-Ascended Fanboy Boom. You'll be seeing him in every series for a while.