Danny Trejo was visiting a friend who was working as a production assistant on the set when he was offered a job as an extra. Edward Bunker recognized Trejo because they served time in San Quentin State Prison together. Bunker helped Trejo get hired as Eric Roberts' boxing coach. Director Andrei Konchalovsky was so impressed with Trejo that he gave him a small role. Trejo later stated that he was staggered to find out that the coaching job earned him $320 per day, which was more than he had ever gotten from a robbery.
Director Andrei Konchalovsky wanted the film to have the look of a documentary. Director of photography Alan Hume and his camera crew put their cameras in odd and unusual positions in order to give the movie a spontaneous appearance. This was to make viewers feel as if they were looking straight out of the train window, or were hanging off the edge of the locomotive.
The film is dedicated to the memory of Richard Holley. Helicopter pilot Rick Holley was killed in a helicopter crash during filming. According to the Alaska Rails website, "his helicopter hit a power line in the canyon north of Tunnel Section". This occurred on March 9, 1985 and was listed as "helicopter accident en route to Alaska filming location".
Jon Voight made himself look "less innocent" by wearing false teeth over his own teeth, to make them look brown-colored and ruggedly damaged. He also placed small obstructions in his nose to flare his nostrils and make it look broken.
In preparing for the role of Manny, Jon Voight spent time with prisoners in San Quentin. He remained in contact with some of them for years afterwards.