John Matthew Matthan started working on Sarfarosh in 1992. Seven years were spent on the research, post production and production till it finally released in 1999.
Mukesh Rishi for the first time did not play a villain. He was quite appreciated for his performance and also nominated for the Best Supporting Actor category at the 2000 Filmfare Awards.
Sarfarosh is Aamir Khan and Naseerudin Shah's second film together. Many people think this was their first time working together, but this is not true, because they have previously worked together in the art house film Holi (1984).
Aamir Khan was the one and only choice for the lead role.
Nawazuddin Siddiqui, who was then a very small time actor, got the small role of a prisoner because the actor who was supposed to do the role did not show up on the day of shooting.