- Panchathanthiram was produced by director S. Ravikumar’s manager P. L. Thenappan.
- The team had initially planned a different film starring Kamal Haasan. A.R. Rahman was roped in to compose songs for the film and some recordings had also taken place.
- Later, the script was changed and the story of Panchathanthiram emerged, with Deva as music director.
- Devayani, who has also worked with Kamal in Thenali, made an appearance in the movie. Her scene is still talked about.
- Krishnamachari Srikkanth was supposed to play the role played by Yuhi Sethu, but the former dropped out.
- Kamal Haasan had already approached Yuhi to act in Thenali and Pammal K. Sambandam, for which Yuhi couldn’t be on board.
- Simran was signed after Kamal was impressed with her performance in Pammal K. Sambandam.
- The shoot started in February 2002 and the team shot in Canada for 17 days.
- In June 2002, the cast and music composer Deva took part in a promotional event in Bangalore, to promote the soundtrack.
- The film faced trouble during censorship and parts of a song featuring Ramya Krishnan had to be cut.
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