Initially, director/co-producer Wolfgang Petersen was denied access to the real-life Air Force One. A telephone call from Harrison Ford to the White House soon changed that.
Gary Oldman's performance earned him the nickname "Scary Gary" during production. However, he did not stay in character between the scenes. Wolfgang Petersen called the filming experience 'Air Force Fun' because of how comedic and genial Oldman and Harrison Ford would be off-screen. He also said that Oldman would suddenly return to the menacing film persona instantly. Ford has since named Oldman as his favorite on-screen nemesis.
Randy Newman was originally hired to provide the film's score. However, Wolfgang Petersen felt it was too serious, to the point of being unintentionally funny. Jerry Goldsmith was hired at the last minute, and had 12 days to come up with an alternative score. Newman later recycled some of his rejected score for Toy Story 3 (2010).
The lead role was written for Kevin Costner, but he was heavily committed to The Postman (1997), and suggested Harrison Ford for the part.