Continuity mistake: Kimble puts the worker's uniform on over his prison uniform, but when he takes it off to tend to his wounds, we only see him remove the worker's uniform, with no sign of the prison uniform.
Other mistake: During the St. Patrick's Day parade, the camera shows a clock that displays the temperature, which is supposedly 23°. None of the spectators or performers we see is dressed for that temperature. They would be way more bundled up than they are. Everybody is dressed for weather in the 40s or so.
Continuity mistake: Kimble dyes his hair very dark to escape detection and dyed hair fades over time. For the rest of the movie his hair noticeably goes from darker shades to lighter shades and back again showing that the scenes were shot non-sequentially on different days with a fair amount of time in between.
Other mistake: When Kimble takes the elevator to the conference to confront Dr. Nichols, he presses a button, but the one beside it is the one that actually lights up. In this particular elevator, the button he pressed is the one that should have lit up.
Continuity mistake: When the bus full of prisoners rolls down the embankment, it finishes up lying parallel to the train track. Yet in the next scene, the bus is clearly lying across the train track.
Continuity mistake: After Richard Kimble first escapes they say he is near Route 15 and Interstate 57 heading towards Berkeley Dam. All these places exist, but Barkley Dam (Kentucky) is around a hundred miles away from these two roads (Illinois), and besides, Berkeley Dam looks nothing like what they show in the movie.
Other mistake: When Dr. Nichols hits Dr. Kimble with a chair, look carefully. As Dr. Nichols swings the chair, it starts falling apart before it even makes contact with Harrison.
Character mistake: Kimble has just finished talking on the phone with his lawyer when the cops hear the noise in the background. They figure out the sound is that of an El-Train. They then start to list the different places that have an El. One of the cities they name is Milwaukee - there has never been an El-Train there.
Continuity mistake: When Kimble goes back to the hospital as a janitor to check the hospital computer, the lady working in the lab is wearing two different dresses. (01:05:15)
Other mistake: After Kimble has been rescued from the train wreck and unchained, he escapes, running alongside a body of water. As Gerard announces to the other officers that there's a fugitive on the loose and gives instructions, Kimble is seen running again, in a replay of the earlier shot. Not only are all the same landmarks in place, but at the end of both sequences, he moves his arm to shake off a branch that's snagged him.
Audio problem: If you listen carefully to the conversation Kimble has with his lawyer, he says "St. Louis" differently in the live version and the police recording, indicating the crew may have used two different recordings.
Continuity mistake: Kimble dives from the top of the dam when Gerard traps him in the tunnel. But in wide shots of Kimble falling, there's no tunnel above the dam. (The tunnel scenes were shot in Chicago, but the location sequences were done at Cheoah Dam in North Carolina - which has no tunnels. The end of the tunnel from which Harrison Ford supposedly jumped was built on the back of a large flatbed truck which was driven out on the top of the dam for the scene).
Continuity mistake: When Kimble is fighting the one-armed man on the train, the one-armed man shoots the metro-cop, then he and Kimble fight some more. Kimble knocks him out with his gun (silver). He goes to check on the cop, sees he's dead so he takes his cuffs and gun (black). He cuffs the one-armed man to the rail puts his gun (silver) into his right pocket, and the cops gun (black) into his left pocket, and then makes his escape. Later on, he dumps the guns into a mailbox, but he pulls the silver gun out of his left pocket, and the black gun out of his right pocket. The guns changed pockets before he dumped them.
Audio problem: When the cops are monitoring Kimble's phone call to his lawyer, Gerrard says, "That's a guy on a PA in the background", or something similar. During the actual phone call that Kimble makes, their is no PA audible in the scene at all.