- Jennifer Garner collapsed on the set in Phoenix twice due to the extremely high temperature, over 115 degrees Fahrenheit.
- Ronald Fleury (Jamie Foxx) mentions the Terrell Tribune newspaper when discussing the terrorist attacks. Terrell, Texas also happens to be Jamie Foxx's hometown.
- Robert De Niro was originally pursued for the role of FBI Director Grace.
- Director Cameo: [Peter Berg] one of the FBI agents at the briefing about the al-Rahmah attack at the Washington DC Field Office
- When Mayes makes a comment about the group of FBI agents being in the jungle, Leavitt calls her Axl, referring to the singer of the band Guns N' Roses who had a hit with "Welcome To The Jungle". "Welcome To The Jungle" is also the German title for The Rundown (2003), a previous movie by director Peter Berg.
- Release prints were delivered to theaters with the fake title "Sand Trap".
- The end of the movie dedicates it to Thomas Aguilar, Lance Gunnin and Nick Papac, all crew members who died during production. Thomas Aguilar (Tom Aguilar, prop maker) died one week after being admitted to the hospital for stomach pain and subsequently discovering he had prostate cancer. Lance Gunnin (construction worker) was killed in a motorcycle accident on his way to the set and Nick Papac (prop master) died in an on-set collision between his Gator all-terrain vehicle and an SUV.
- The production team had originally wanted to shoot the film on location in Saudi Arabia, but political and logistical issues made this far too difficult. Instead, Tom Duffield and the production design team re-constructed exterior urban scenes for the chase and shootout on an empty lot near Mesa, Arizona, using photographs from the internet and some that director Peter Berg had taken on a visit to the country prior to filming. Some additional on location photography was shot in Abu Dhabi, United Arab Emirates. This includes the Prince's palace and larger exteriors with skyscrapers, major city streets and highways.
- Peter Berg gave small roles to people involved in both his film and TV versions of "Friday Night Lights". Tim McGraw, who was in the movie, plays Aaron Jackson, while two stars of the TV show, Kyle Chandler and Minka Kelly play Agent Francis Manner and Miss Ross the schoolteacher, respectively.
>>> WARNING: Here Be Spoilers <<<
Trivia items below here contain information that may give away important plot points. You may not want to read any further if you've not already seen this title.
- SPOILER: An earlier draft of the script had Sgt. Haytham being extremely disaffected after being tortured by his own government for his suspected involvement in the bombing. The earlier ending had Al-Ghazi surviving, but instead Haytham says goodbye to the FBI team at the air base with a hidden bomb strapped to his chest. Sykes tackles Haytham away from the group, but Haytham detonates it before Sykes can get clear.
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