According to production team member Kishore Malhotra, the total cost of producing the series was 9 crore (US$1.2 million). Casting for the series began in 1986 and shooting started off in mid-1988. Show was shot mostly at Mumbai's Film City, and the grand battle of Kurukshetra was shot in Rajasthan, with thousands of extras to fill the screen.
Mukesh Khanna who wished to play Karna but was signed for Dronacharya. After Karna, he then showed slight interest in playing Arjun but when Vijayendra Ghadge dropped his role of Bhisma, Producer B.R. Chopra approached Khanna to play the role.
Around six actresses were shortlisted for the role of Draupadi, including Juhi Chawla, who opted out of the show as she had bagged lead role in the film Qayamat Se Qayamat Tak opposite Aamir Khan. Ramya Krishnan and Roopa Ganguly were the final names, and at last Roopa Ganguly was chosen, as her Hindi was good.
Actors who played Nakul and Sahadev are real life brothers Sameer Chitre and Sanjeev Chitre.
During it's original run, it is said that people would stay glued onto their TV sets and streets would be literally empty.