Aamir Khan initially turned down the film but was heavily persuaded by director Dharmesh Darshan to sign on. Dharmesh told Aamir that the film had huge commercial potential. Eventually, Aamir agreed with the idea that the film could be very successful and then later signed on. Darshan was right about the commercial promise, as the film became the biggest box office hit of 1996 in India. Karisma's makeover was so good and her performance so powerful that everyone called it 'Rani Hindustani' after it was released and this upset Aamir.
Juhi was offered the movie but she was reluctant to work with Aamir with whom a misunderstanding had developed.
Aishwarya Rai Bachchan was offered the lead heroine role and was tempted to take it, but she wasn't looking into an acting career at the time and was busy with her studies.
The first cut of the film was 4 hours and 25 minutes long.
Pooja Bhatt was to sign the film, but Aamir Khan who had broken up with her a few years back, wanted director Dharmesh Darshan to sign someone else. Darshan approached Juhi and Aishwarya who refused for different reasons. And then Karisma was signed.