Continuity mistake: When Chuck first goes over and sees the cave, it changes the camera angle and the sunlight is significantly dimmer and more orange, indicating a sunset.
Continuity mistake: When Chuck is attempting to start a fire his hands are so badly scratched/blistered that he ties a piece of fabric around one of them. Once he has started the fire and is doing his little dance on the beach his hands face the camera and there is not a mark on them.
Continuity mistake: The scene where Tom Hanks goes inside the cave for the first time during the storm, he has the flashlight from the dead pilot with him. The flashlight is in front of him when he sits down, but you can see shadows on the rock wall beside him in the wrong places.
Continuity mistake: When we first see Chuck washed up on the island in daylight, as he gains consciousness and awakens inside the life raft, he is clean shaven. A moment later when he is walking down the beach collecting the FedEx boxes, he has grown a full day's worth of beard stubble.
Continuity mistake: In the scene where Chuck is floating in the water on the raft you can see that the raft is yellow. When he gets on land and puts the raft up by the trees it is orange. Through out the whole movie you can see that the raft changes from yellow to orange.
Revealing mistake: As Tom Hanks escapes from the sinking aircraft, it shows him still underwater, looking back and the plane breaking apart. It shows an AKE-shaped container (which fits the contour of the bottom of the aircraft) which has no markings at all, it appears to be just a computer generated solid with no color.
Factual error: As the plane hits the water, Hanks is pushed back into the cargo area. He travels through an empty passageway between rows of containers. Though this load configuration is possible, it is not used because it makes no sense. Furthermore, he finally stops against a container that reads AEE7480FX. This creates a couple more problems, as AEEs are not only no longer in use, but they were belly containers, with an angled side on the bottom that fits the contour of the bottom of the aircraft. There could not have been one of these on the topside of the aircraft.
Factual error: On Tom Hanks' doomed flight, there is no smoke curtain or solid bulkhead in place. This is a heavy, opaque curtain or solid wall that separates the the topside cargo area from the seating area, designed to keep smoke from a fire away from the crew. On DC10/MD11 aircraft, this is generally a solid bulkhead, and on Airbuses a curtain. This plane should have been grounded until one was installed.
Factual error: As the plane hits the water, Chuck falls backward, toward the rear of the plane. This violates the physical law of inertia. He actually would have continued traveling forward toward the incoming water.
Continuity mistake: When Chuck first lands on the island he gets up and looks around.. he starts to walk down the beach and after a little while he looks back and sees his own footprints. He turns back around and the camera cuts to a wider shot.. you can clearly see his footprints get washed away by the waves. The camera zooms in as he picks up a FedEx box and zooms back out as he turns around again and his original footprints are there.
Factual error: In the scene where a boy runs on the streets of Moscow, he passes by the famous Moscow landmarks: St Basil's cathedral, Moscow State University, Big Stone Bridge etc. In reality it would have taken him a good four or five hour run to do that.
Factual error: Since the can that breaks through the net is an AMJ on the right side of the plane, they must be in either a DC-10 or a MD-11, as those are the only 2 planes that are wide enough to fit AMJs on the right side. However, when Hanks is in the ocean looking back at the plane, it shows the tail as it is sinking into the water. It shows enough of the tail (which has suddenly lost all its paint, in particular the FedEx logo) to determine that there is no intake on it, which signifies that they were on an AirBus.
Audio problem: In the scene where Chuck is throwing coconuts at the rock, the sound of the coconut hitting the rock comes after the coconut actually hits it.
Factual error: In the crash scene, Tom Hanks floats to the back of the plane as it fills with water. This could not happen due to a smoke barrier that is installed on every FedEx DC-10 and is a solid barrier between the crew and freight.
Continuity mistake: It already shows us that the wings of the plane are submerged in the sea. When Hanks surfaces, he turns around to see an engine (attached to a wing) bearing down on him. Physically this would be impossible even if it didn't show the wings, as the aft part of the plane would have been too heavy to hold that much of itself above the water.
Revealing mistake: When Chuck is writing on the rock waiting for the wind to change direction, you can see that when the wind changes direction the trees behind him are duplicates.
Factual error: The orientation of the plane is all wrong. Hanks goes into the bathroom, which is located aft of a crew door, and against the front of the cargo area. The bathroom on all the wide body aircraft (Airbuses, DC-10, MD-11) is located between the cockpit and the jumpseat area.
Other mistake: When Tom Hanks cuts his hand and loses his temper, he picks up the volleyball with a bloody hand and throws it. When he picks it up, you can see that his fingers are spread. When you see the handprint that he makes "Wilson" with, you can see that the fingerprints are together and parallel.
Continuity mistake: Throughout the film, Tom Hanks has a dark lump above one of his eyebrows. This seems to come and go from scene to scene.