Akshay Kumar was ready to opt out of the film if he had to mouth anti-Pakistani lines - he didn't want to hurt the feelings of his Pakistani fans. He rejoined the cast when his lines were rewritten.
Akshay Kumar asked director Anil Sharma to give a disabled fan of his a role in the movie. The fan, Puran Chauhan, who lost his leg in a roadside accident at the age of five, was given a small part.
Five ships were used for the starting scene and sailed from Vishakapatnam, with shooting happening as far as 200 km from land. Quite a few of the crew were noted to have gotten sea sick.
The scene where sea water gushes into the ship after being torpedoed, was shot inside the Indian Navy's "Damage Control Simulator" at the land base INS Shivaji.
Bobby Deol plays a dual role of a father and son earlier the father's role was to be played by Shah Rukh Khan who later opted out and Deol played both the roles.