According to Johnny Yong Bosch, the original Power Ranger cast were not even notified that they were being replaced halfway through the season - they found out by seeing an ad for their jobs in the newspaper.
Carol Hoyt originally replaced Hilary Shepard during filming, because Shepard was pregnant between Turbo Power Rangers (1997) and returning for the episode "The Darkest Day" of Power Rangers Turbo.
Blake Foster was a huge fan of the show and was absolutely thrilled when he was offered the part of the Blue Ranger. Even at Power Morphicon in 2010, he said that being a Power Ranger was every kid's dream and that he kept his helmet and costume.
The first Power Ranger show in which the rangers don't say "It's morphing time" when they morph.
Divatox was suppose to be revealed as Dimitria's twin sister.