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James Brolin was attached to play the Col. Samuel Trautman role after Richard Crenna died of pancreatic cancer in 2003, but the role was written out of the script. Sylvester Stallone considers the character to have died on the same day as Crenna, who appears in an archival flashback in Rambo.
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Stallone intended to make this film before Rocky Balboa, but Rocky was green-lighted by MGM, so he had to put Rambo on hold.
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The first Rambo film directed by Sylvester Stallone.
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The first Rambo film without the music of Jerry Goldsmith, who died in 2004.
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During its long development process, 'Rambo' went through a number of story premises. One un-produced script featured Rambo living a quiet life with wife and child, until white supremacists kidnap his family. Another script found Rambo trying to stop a hostage situation at the United Nations, where he is working as a diplomat, when terrorists (including Rambo's adopted son) take hold of the UN headquarters in New York.
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This is the first Rambo film without a companion novel by David Morrell, Rambo's creator. Morell wrote the novel "First Blood", the basis for the first Rambo film, and novelizations of 'Rambo: First Blood Part II' and 'Rambo III'.
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Ted Kotcheff who directed First Blood, the original of the Rambo series, acts as a technical consultant on this particular installment.
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In many countries, the first installment, First Blood was re-titled "Rambo", so the title for the fourth installment had to be changed accordingly. In several countries, including France and Germany, the film is called "John Rambo." In Russia, the film is called "Rambo 4."
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Julie Benz was cast as Sarah because Sylvester Stallone was a big fan of the TV show Dexter in which she stars.
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Rambo was banned in Myanmar (formally Burma), and bootlegs are a hot item. Burmese Freedom Fighters have even adopted dialogue from the movie as battle cries, most notably "Live for nothing, or die for something." Sylvester Stallone said "That, to me, is one of the proudest moments I've ever had in film."
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Averages 2.59 killings per minute.
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Odeon, a UK cinema chain with more than 100 screens, refused to show the film for 'commercial reasons'.
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Originally, Rambo was supposed to hold the M2 .50 caliber machine gun in his hands and fire it, but when fully assembled the .50 weighed 120 lbs. Stallone was still capable of holding and firing it but it was too cumbersome for quick movements, so they mounted it on the back of a jeep instead.
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During the montage after Rambo is asked to transport the mercenaries, it shows the alternate ending to First Blood where Col. Trautman (Richard Crenna) would have ended Rambo's revenge on Teasle by shooting him in the abdomen.
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Maung Maung Khin, who played the Burmese dictator Tint, fought for the Karen Rebels in real life. He was afraid his family would be murdered if he took this role, but he took it anyway.
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The first Rambo film where Rambo uses a pistol. Also the first Rambo film without a helicopter. Most notably, it is the first Rambo film completely without a scene in which John Rambo is without his T-shirt, showing his muscles. This is due to Sylvester Stallone's, extensive tattoo work on both shoulders, which he started getting in late July 2007.
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The first Rambo film to break the pattern of greatly escalating the budget from one film to the next, it cost $50 million, while it's predecessor Rambo III cost $63 million.
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Sylvester Stallone specifically wanted the film to be set in the midst of the most brutal ongoing global conflict that was basically ignored by the public and media. After ruling out established (and well-known) conflicts in the Middle East, Latin America and Africa, Stallone talked to international experts who told him about the Burmese junta's mass murder of the Karen people. He then set the movie's storyline in the middle of this genocide.
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The only Rambo film so far in which John Rambo is not captured by someone, i.e.- police, military.
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At different points in script development, Luc Besson, Richard Donner, and James Mangold were considered to direct.
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The name 'Rambo' is mentioned only once in the whole film, namely when Rambo is awoken by pastor Arthur Marsh.
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In the nightmare sequence, just before Rambo learns that the group has been kidnapped, we see a short glimpse of Rambo's suicide, a scene that was cut from the original film First Blood.
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Spoilers 

The trivia items below may give away important plot points.

Highest body count of any Rambo film (236).
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