Actor Allusion: A fake passport for Nina Myers in Season 3 is under the name "Sarah Berkeley"- Sarah Clarke's married name (she married fellow cast member Xander Berkeley, who played George Mason).
Paul McCrane's characters tend to die painful onscreen deaths. Guess what happens to Graem Bauer?
Dawson Casting: Elisha Cuthbert started off older than the aged 16 Kim, but is now younger than the character she plays.
Development Gag: The wedding side story in Season 2 was a nod to the original concept that 24 be a comedy about preparing for a wedding.
Development Hell: A feature film adaptation of the series has been in the works for years.
Executive Meddling: The reason Keeler survives the crash and subsequently disappears was thanks to a network mandate that the writers couldn't kill off a sitting President, as was originally intended in the Air Force One attack.
And for Season 6(?), Lord Denethor was working in the Russian government as an inside man for the terrorists, showing that he can be a bastard even without Sauron's corruption. Or maybe it was Walternate all along.
Scar is an assassin who gets run over by a frickin' BULLDOZER driven by Jack in Season 7.
Daniel Jackson started sleeping with a White House aide to steal info for the Russians? Also, one of Ba'al's clones turns up as a sniper in Season 8. Jack does SG-1 a solid and caps him.
Obviously Dennis Hopper as Drazen in season one. And who is his son? Why, none but Castiel.
And Lou Diamond Phillips is Drazen's jailer. Young Guns reunion!
To non-Canadians, he's Kumar's brother. See above.
So what does RoboCop do in his spare time? Oh, become Jack's mentor and tries to kill him multiple times (season 5). But even he falls prey to Jack Bauer's prowess. Next up, Chuck Norris.
Four episodes left in the series, and the audience is still asking if Milton is still stuck in the wall.
In the later episodes of Season 8, Jack has to enlist the help of Mr.Blonde.
Colonel Young is Michelle Dessler's brother. (Funnily enough, Reiko Aylesworth turns up in SGU in return.)
When D. L. Hawkins is forced to play Russian Roulette with Jack, he chooses not to phase the bullet through his head.
Disclosed memos from within the former Bush administration suggest that, if 24's torture methods didn't inspire the initial events at Abu Ghraib Prison and Guatanamo Bay Prison Camp, they at least inspired their justification and continuation to this day.
On a less controversial note, the suspects of the Abu Ghraib abuses claimed 24 as inspiration for their tactics, and military intelligence instructors have complained to reporters that they have to drill 24 and its depiction of torture out of the heads of new students.
The set of CTU LA also inspired the design of the new Joint Counter-Terrorism Center in Washington, DC.
The Other Marty: Margo, the antagonist of Live Another Day, which was originally supposed to be played by actress Judy Davis. As principal photography began though, Davis was forced to drop out because of family concerns, so the role was recast to Michelle Fairley.
Real Life Relative: The actors who played George Mason and Nina Myers married between the first and second season, making the interrogation between them in the latter rather interesting to watch.
Rumor has it that they toyed with the idea of Donald Sutherland as Jack's father.
Season 6's Darren McCarthy was initially cast as Eddie Izzard, but he was forced to cancel due to scheduling reasons.
The series was originally conceived as a comedy about preparing for a wedding. This would soon afterward see the light of day as Big Day, though the show quickly crashed and burned.
The actor who played Kevin Carroll (the false Alan York in the first season), Richard Burgi, was originally cast in the role of Jack Bauer. He would have had that role if they hadn't been able to get Kiefer. Once Sutherland was brought on board, Burgi accepted the role of Carroll.
At one point, Joel Surnow wanted to acquire the rights to The Da Vinci Code in hopes of working it into a plotline for the show's third season, but Dan Brown rejected him. How he would have worked Jack Bauer into a story about Leonardo da Vinci, Pagan cults and Jesus' family is anyone's guess.