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Henry Winkler, who became a sensation as "Fonzie" on Happy Days, was considered for the role of Danny Zuko. However, he turned down the role for fear of being typecast.
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Susan Dey and Deborah Raffin were the first choices for the role of Sandy (Dey declined the role after her manager advised against it). Marie Osmond later claimed on Larry King Live that she had been also been offered the role but declined "on moral grounds" though she later admitted this to be untrue.
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Due to a zipper breaking, Olivia Newton-John had to be sewn into the trousers she wears in the last sequence (the carnival at Rydell).
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Set in high school, most of the principal cast were way past their teenage years. When filming began in June 1977, John Travolta was 23, Olivia Newton-John was 28, Stockard Channing was 33, Jeff Conaway was 26, Barry Pearl was 27, Michael Tucci was 31, Kelly Ward was 20, Didi Conn was 25; Jamie Donnelly was 30, and Annette Charles was 29. Only Dinah Manoff, Lorenzo Lamas, and Eddie Deezen, all 19, were still teenagers.
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Randal Kleiser hated the song "You're The One That I Want" saying it "sounded awful".
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