Chuck cuts the toes off of Albert's shoes. When he enters the cave for the first time, the toes aren't cut out.
When Chuck Noland is in the airplane prior to the crash, he is wearing khaki pants. After the plane crashes by the island, when he wakes up on the beach on the island, he is wearing black pants.
When Chuck first finds the port-a-potty piece that washes up on shore, the first shot revealing his left thigh does not bear the long scar shown earlier in the movie. Yet afterwards, the scar appears once again on his left thigh.
When Chuck first spears a crab, he shows the crab then reaches down, out of camera range, and breaks off a leg. When he brings the leg up into camera range, it is a much larger leg than was shown on the original crab.
When Chuck carves HELP in the sand with his foot, you can see the high tide mark of the sea weed is below the letters and the sand is obviously soft indicating it is above the high tide mark. However, in the next scene when the tide has come in and washed half the letters away the high tide sea weed mark is up above the letters.
When the plane is going down, Chuck watches the ocean's surface approach through the pilots' windshield. When the plane strikes the water, he is thrown backward into the cargo area. In reality, he would have been flung forward, into the cockpit, and likely would have died from the impact.
As the FedEx MD-11 dives toward the ocean, none of the alarms that should go off during a steep dive (i.e. Excessive Sink Rate, GPWS) are going off. All
aircraft operating out of the United States since 1972 have been equipped with such alarm systems to help prevent crashes.
When Chuck goes to use the restroom in the airplane, there is a small brown UPS sticker on the bottom right of the mirror on the FedEx airplane.
When the plane crashes in the ocean, the engine is still running by the time Chuck emerges from the water. Airplane engines are powered by electrically powered fuel pumps and would not be able to run under water.
The invoices on the FedEx packages that Chuck recovers are domestic (USA) FedEx manifests. International manifests have always been much larger and more detailed.
The plane was obviously having problems flying through a storm before going down, but Kelly told Chuck that FedEx decided the plane went down due to some unmarked hazardous material in one of the packages.
The plane's only problem regarding the storm were lack of communication and 'flying blind.' The undeclared hazardous material (i.e. corrosive or combustible substances compromising hull integrity) caused an explosive decompression, dooming the aircraft to crash. Hence one of the pilots shouting, "Explosion!" as the hull is ruptured.
Early in the movie, Kelly gives Chuck a pocket watch, telling him her grandfather, who was a railroad crewman, used it on the Southern Pacific Railroad. Chuck subsequently winds and sets the watch to local "Kelly Time" just before departing on the plane. The watch shown is a stem set in a hunter style case (i.e. has a sprung, hinged cover that closes over the watch face). This is not a real railroad watch since the specific design was controlled by federal regulations, and would have never been allowed to be used on the job by a railroad crewman. Among a long list of standards, they were required to have an open face (hunter case hinged clamshell covers were prohibited) and be "lever set." That requires the watch back to be opened, exposing the movement, and a lever moved in the movement to allow setting the time by turning the crown. (The crown cannot be pulled out from its winding position for time setting as was common with non-railroad watches and is the standard setting method today.) This prevented a railroad crewman from accidentally changing the time while winding the watch. It also allowed for station masters to control setting crew watches to calibrated time standards as they would seal the watch back after setting it. Had they used a proper railroad pocket watch, Chuck wouldn't have been able to wind the watch and so easily set its time during this scene.
After Chuck makes fire and is eating crab, you can see the firewood is cut by a saw.
When the FedEx MD-11 is diving towards the ocean, the First
Officer's altitude indicator (visible by his left shoulder) shows that the aircraft is climbing gently.
When Chuck enters the cockpit, the attitude selection of the Primary Flight Display should be completely brown because the plane is in a steep drive. It shows a pitch indication of zero, or level flight.
When Chuck starts paddling his wooden raft towards the breakwater, palm trees can be seen repeatedly on a length of land that is apparently not part of his small island.
When Chuck was building the raft to leave the island and ran out of plant fiber to make rope, he states that he has searched the entire island and couldn't find any more plants; however, there was a plant right behind him.
Kelly, when talking to Chuck after he comes home, talks of the Tennessee Titans Super Bowl appearance. That Super Bowl was Super Bowl 34, which took place on January 30, 2000, but when Chuck was found and returned home, it was still 1999.
Wilson's box bears the AVP (Association of Volleyball Professionals) logo. Spalding was the "official" manufacturer in 1995, not Wilson.
Chuck was lost in 1995, yet his Jeep Cherokee is clearly a 1999 model. The newly styled front end first appeared in 1997 models, and the wheels were first available in 1999. The dashboard and instrument cluster are from the newer model. The front blinkers on the 1995 Cherokee were attached to the headlights, not on the front fender.
The thunder on the island occurs at the same exact instant as the lightning, even though we can see the lightning is off in the distance.
In the theatrical version, the audio/visual sync is off when Chuck pounds coconuts against a large rock.
When Chuck is walking to the caves for the first time and his feet are being cut on the rocks, you can see a flash of the tube sticking out of his pants that are used to squirt fake blood into the water.
When Chuck is walking through the water to the cave for the first time,there is a shadow on his right hand side from something, or someone standing just outside the view.
When the boy runs on the streets of Moscow delivering the package to Chuck, he passes by several Moscow landmarks: St. Basil's Cathedral, Moscow State University, Big Stone Bridge, etc in a short span of time. In reality, it would've really taken him a good four or five hours to pass by all those landmarks.
Towards the end of the movie, Kelly tells Chuck his island was 600 miles south of the Cook Islands. In reality, there is no land between the Cook Islands and Antarctica.
At the end of the movie when looking at a map on his hood, the road sign shows FM 1265 [Farm to Market Road 1265]; however, FM 1265 was retired in 1990 and the portion was re-designated as part of Texas State Highway 23.
In the cave, Chuck has made an analemma, which is impossible without a precise watch, which is stated he didn't have. The analemma is a graph of the difference between solar time and civil time, in any case he only had access to a solar time reading.
Chuck plans for his launch by looking at where the Sun is shining on a rock in his cave. The spot of light makes a figure 8 as the year progresses. But the light spot would have to be marked at the same time each day, as it would also move across the rock throughout the day. It is unlikely that it just happened to be that time of day as he looked at his "calendar", and it is unlikely that he knew what time it was since his watch did not work.
In the beginning of the movie he is haranguing the Russian FedEx office, as an example, he sent a stopwatch clock to himself and ranted how, as he opened it, it took 87 hours to reach here and that isn't good enough. Why would he be chewing out the receiving end for what he considers too long to get there? Shouldn't he be in New York yelling at that office for taking so long to get it across the ocean to Russia?
Figure skates are like pencils: they are dull when fresh, and have to be sharpened before being used for the first time. The sharpening also has to be maintained periodically, and Chuck's use of the skates in survival skills would have greatly damaged them to the extent that they would no longer be usable. There is no credible way Chuck could've used the skates as survival tools, especially given the four-year time span and lack of a skate sharpener.
Apparently Chuck can't remember the looks of Kelly when he's drawing a picture of her face on the wall of the cave, but he has a clear picture of her in the lid of the pocket watch she gave him prior to takeoff and that he has been staring at multiple times since landing on the island.
When Chuck is on the island opening the packages, when he opens the ice skates, you can clearly see the boom mic and operator in the reflection of the skate.
Chuck shipped a package from Memphis, Tennessee to Russia. When he opens the package, a timer comes out and he stops it 87 hours 22 minutes and 17 seconds. He goes on a rant about how it's unacceptable and how certain things have happened in that time frame. As a shipping carrier manager, he should know that it takes several days for international packages to go through customs.
When Chuck is talking to Wilson after retrieving the hanging rope from the cliff, he says "I'm glad we tested it, it wouldn't have been a quick little snap. I would have landed on the rocks". But given the fact that neither the tree nor the rope broke, there's no reason he should have thought that to be the case.