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Pre-production of the film began in late 2006 with Akshay Kumar being signed first, and Saif Ali Khan and Kareena Kapoor next. In early 2007, Anil Kapoor was signed on to play a negative role in the film. This film marks the return of Kumar and Kareena Kapoor to the Yash Raj banner after the former's Yeh Dillagi (1994) and Dil To Pagal Hai (1997), and the latter's Mujhse Dosti Karoge! (2002). Anil Kapoor also makes a comeback to the Yash Raj banner after 16 years. His last film with the banner was Lamhe (1992).
Apart from the major star cast, Khan's son, Ibrahim, will be seen making his debut with the film, and is reported to play his son. All the actors will be seen sporting new looks designed by designer Aki Narula, with Kapoor in a very glamorous role and reportedly donning a bikini.
In June 2007, the cast began filming in Kerala, and later continued shooting in Laddakh and Rajasthan.[9][10][11] Pictures of Khan and [Kareena] Kapoor were taken in September 2007 while shooting for the film in the Fort area of Mumbai. Some portions of the film were later shot in the city of Haridwar on the banks of the river Ganges and Greece.
The first promo was shown on November 30, 2007 with the release of Anil Mehta's Aaja Nachle. In a recent poll conducted by IndiaFM, Tashan ranked first on the list of "Most Awaited Movies of 2008"
