The sedan Col. Austin and his friend are issued is a shiny new red Chevrolet. Near the end, the Col. turned the car over on a henchman. In the closeups, the paint is dull, scuffed and the bodywork dented. Not the same car at all.
A large rip suddenly appears on the back of Fred Sloan's jacket just before Steve Austin knocks his "face" off. This rip is where the electrical pyrotechnics go off about one minute later.
The photograph of Steve Austin that the robot's makers show the robot Sloan changes from shot to shot.
When the bad guys set off an explosive charge to blow out the front tire on the Chevrolet Col. Austin and his friend are driving, the closeup of the tire blowing is that of of a bright red Volvo, a completely unrelated car. Check the hubcap difference--note the "V" logo.
Steve and Fred are driving in a red Chevrolet Impala/Caprice with a red interior, but the shots of the dashboard, when Fred floors the accelerator and the speedometer increases, appear to be from a Chrysler-manufactured car (note the design of the gearshift indicator and steering wheel) with a black interior.
The anti-ballistic missile being test fired is actually a TOW missile, used by the Army to engage tanks primarily by mechanized infantry units.
Army helicopters do not make a police siren sound from the air. Even if they did the noise from the rotor would drown it.
After Steve drops the steel girder, it bounces and wiggles as if made of rubber.
After Steve skewers the robot with the I-beam, the electrical sputtering is heard in a series of repeating sound clips, obviously the same sound effect being played over and over.
The shots of running data tape reels giving the robot information are almost always squeezed, indicating that they are stock footage from a movie shot in CinemaScope style widescreen. As was the case many times, 70's TV shows using this type of stock footage often neglected to unsqueeze it.
After the car crashes into the ditch there is some visible damage the the front of the car. The hood does not line up with the front grill. The car Steve lifts has no damage and is obviously a different car.
As the robot shifts the car from the rear Steve is walking towards him. The car is not moving at the front. Even slightly the car should move and change angle at the front as well.
Camera lighting is reflected in the car as it drives along to the missile launch facility.
The robot makers' plan to substitute Major Fred Sloan with a robot depends entirely on him stopping at a particular gas station and going to the bathroom (the robot duplicate is already waiting inside the bathroom before Sloan and Steve get there, as is a truck to kidnap Sloan). Although it is implied Sloan was given a tainted cup of coffee by a military officer who is secretly working for the villains, it's still a ridiculously long shot for such an elaborate plan.
During the final programming and tests on the robot, one of the villains asks his associate about "the activator cards", yet Steve was bringing only one card to the test site.