Casting
Singer Olivia Newton-John had done little acting before this film. She appeared in the 1970 film Toomorrow - a science fiction musical that pre-dated her initial chart success with 1971’s If Not For You. Cast with Newton-John and three male leads in an attempt by Don Kirshner to create another Monkees, the film failed miserably; this led Newton-John to demand a screen test for Grease to avoid another career setback. The screen test was done with the drive-in movie scene.
Two actors who were seen for the film were Henry Winkler and Marie Osmond. Winkler, who was playing Fonzie on Happy Days, was originally chosen to play Danny, but, having twice already played similarly leather-clad 1950s hoods in 1974’s The Lords of Flatbush as well as Happy Days, turned down the role for fear of being typecast. Osmond turned down the role of Sandy because she did not like the fact that Sandy had to “turn bad” to get the boy. Adult film star Harry Reems was originally signed to play Coach Calhoun; however, producers got cold feet weeks before filming and replaced him with Sid Caesar.
Dinah Manoff passed her audition without being given a singing or dancing tryout. Her skills in those areas proved limited, so she was moved into the background during the song numbers.
Cars
Danny’s race car is a modified 1948 Ford Deluxe.
Leo’s car was a modified 1949 Mercury.
Frenchy’s car is a 1956 Dodge Custom Royal
Danny’s Drive-in car was a 1949 Dodge Wayfarer.
Costumes
Danny’s blue windbreaker at the beginning of the film was intended as a nod to Rebel Without a Cause (1955).
Because of a zipper breaking, Olivia Newton-John had to be sewn into the pants she wears in the last sequence (the carnival at Rydell), and was unable to remove the trousers until the filming of that scene was over.
Stockard Channing’s original costume was going to be a purple blouse and green skirt. Unfortunately, it was a bad fit and she had to wear black.
Didi Conn was originally asked to dye her hair golden, but refused. She also refused to have her hair dyed green at the Carnival ending, stating in the DVD that she was supposed to explain to the group that she got into a pool that contained too much chlorine (referencing a joke from the original play) and colored her hair into a bright green color. She refused, stating in the interview “Don’t turn me into a joke.”
