1. Olivia Newton-John insisted on having a screen test with john travolta.

Producer/co-writer Allan Carr met Olivia Newton-John at a party thrown by fellow Australian singer Helen Reddy and was “completely smitten” and begged her to sign on for the part. Travolta told The Morning Call that he rallied for Newton-John to get the part, too. Not trusting her good fortune or her acting (her previous film, Tomorrow, had been released back in 1970), Newton-John requested a screen test with Travolta to make sure they had chemistry.

2. Andy Warhol and an adult film star would have been cast if Paramount hadn’t stepped in.

Carr wanted Warhol to play the art teacher. One unnamed studio executive said he would not have “that man” in the movie, which Carr interpreted as the executive having a personal vendetta against the legendary artist. Carr also wanted porn star Harry Reems to play Coach Calhoun and offered him the part after a screening of Casablanca at Hugh Hefner’s mansion. The studio wouldn’t have it. “They bounced me out of the cast,” Reems said. “They thought they might lose some play dates in the South.” Carr felt so badly about it that he wrote Reems a personal check for $5000.

3. Most of the main actors were far too old to be in high school.

Stockard Channing (Rizzo) was 34 when the film was released. Newton-John was 29. Jeff Conaway (Kenickie) was 27. Travolta was 24. Jamie Donnelly (Jan) was 30 during filming, and had to dye her hair from her premature grey to black. Her hair grew back so quickly that her roots had to be colored in with a black crayon every day.

4. Lorenzo Lamas landed a role when a president’s son backed out.

Gerald Ford’s son, Steven, was too nervous to play Tom Chisum, Sandy’s jock boyfriend, who had a grand total of zero lines. Lamas (later Lance Cumson on Falcon Crest and Hector Ramírez on The Bold and the Beautiful) jumped at the chance, agreeing to lighten his dark hair because he looked too much like a T-Bird. "I would have dyed it green, fuchsia, anything," Lamas told People.

5. Rizzo’s hickeys were real.

Conaway gave Channing a real hickey because he wanted it to be authentic. Conaway was also so infatuated with Newton-John that he was tongue-tied whenever she was around. He later married Olivia’s sister, Rona.

6. "Greased Lightnin'" was supposed to be sung by Jeff Conaway, not John Travolta.

Travolta’s two conditions for agreeing to play Danny were that he could sing “Greased Lightnin',” even though Kenickie sang it in the stage production; and that he had to have “blue black hair like Elvis Presley and Rock Hudson in the movies” because “it’s surreal and it’s very 1950s.” The star also argued with Kleiser over the end of the song “Sandy”; he wanted a close-up of himself instead of the cartoon shot of a hot dog diving into a bun. Kleiser got his way. 

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7. Coca-Cola signs were (mostly) blacked out.

Carr made a promotional deal with Pepsi; the set decorator didn't know that. When the producer saw footage from the movie featuring Coke products he went “ballistic,” according to Kleiser. The Coca-Cola logos were blocked out with an optical printer. They couldn’t alter the Coke cooler, because it was impossible to cover with the technology available at the time. Pepsi never complained. They would have unblocked the Coke signs when the Pepsi deal expired before the 20th anniversary re-release if the original print hadn’t been lost. 

8. George Lucas helped get the movie re-released.

In 1997, Kleiser called Sherry Lansing, then head of Paramount, and insisted that Grease had to come back again for its 20th anniversary. Lansing informed Kleiser that George Lucas had called her a few days earlier and said that out of all of the movies in the Paramount vault, Grease is the one that should come back. The Star Wars creator explained that every nine-year-old he knew watched a VHS copy of Grease every day. 

9. That Elvis Presley lyric is creepy.

In “Look at Me, I’m Sandra Dee,” Rizzo sings “Elvis, Elvis, let me be, keep that pelvis far from me,” while looking at a picture of The King. That scene was shot on August 16, 1977—the day Presley died. “It was very eerie,” Kleiser told The New York Post. “It was all over the news, so everyone knew. We did this number, and everybody kind of looked at each other like, ‘Yeah, this is creepy.’” When Carr first bought the film rights to Grease, he envisioned Elvis as Danny and Ann-Margret as Sandy. According to Broadway.com, Presley was offered the role of Teen Angel but turned it down. 

10.Travolta got more of the stage script into the movie.

Jim Jacobs and Warren Casey, who wrote the original musical’s book, weren’t invited on set during production of the movie. Travolta had played Danny more than 100 times on the road doing the musical, and gradually got more lines from Jacobs and Casey’s version into the film, which was written by Carr and Bronté Woodard. When Travolta didn’t think a line of dialogue was working, he would quote a line from the original, and Kleiser would tend to agree and use that line instead. 

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