10 Famous Actors Who Were Almost Fired During Filming

10 Famous Actors Who Were Almost Fired During Filming

From bold creative choices to clashing with directors, and even personal struggles that threatened entire productions, these stars nearly got the boot mid-filming. But instead of being replaced, they turned the odds around—and in some cases, created performances that defined their careers. Here are 10 actors who were this close to being fired, and the wild stories that went with it.

1. Robert Downey Jr. — Iron Man

When Marvel cast Robert Downey Jr. as Tony Stark, not everyone was cheering. Executives worried about his troubled past with substance abuse and wondered if he could stay reliable during such a massive production. For a while, replacing him was a very real possibility.

Jon Favreau, the film’s director, fought hard to keep Downey. He saw the charm, wit, and resilience that perfectly matched Tony Stark’s personality. Against all odds, Marvel gave him the chance.

The gamble paid off beyond anyone’s imagination. Downey not only completed the role, but his performance launched the Marvel Cinematic Universe and transformed him into one of the highest-paid actors in Hollywood. Nearly being fired ended up being the spark that fueled his biggest comeback.

2. Harrison Ford — Raiders of the Lost Ark

Indiana Jones is almost impossible to imagine without Harrison Ford, but the role wasn’t always secure. Ford’s stubborn streak and clashes with Steven Spielberg over how the character should be portrayed created plenty of tension on set.

There were whispers that Ford might not last the entire shoot. Spielberg and George Lucas even discussed whether a replacement would be needed if things escalated further.

Thankfully, Ford’s natural charisma shone through. His combination of ruggedness, wit, and fearlessness made Indiana Jones unforgettable. What once looked like a risky gamble ended up being one of the most iconic character-actor pairings in cinema history. Sometimes, friction behind the camera creates lightning on the screen.

3. Jennifer Lawrence — The Hunger Games

Taking on the role of Katniss Everdeen should have been a slam dunk for Jennifer Lawrence, but the early days weren’t smooth sailing. Some studio executives questioned whether she was “big enough” of a star to carry a franchise of that scale.

On top of that, when initial photos and promotional material came out, fans were vocal about whether she matched their vision of Katniss. The backlash made the studio nervous, and for a brief moment, there was chatter about recasting.

Lawrence quickly silenced all doubts once cameras rolled. Her fierce, grounded portrayal of Katniss not only won over fans but cemented her as one of the most bankable stars of her generation. Being nearly replaced only made her success sweeter.

4. Sylvester Stallone — Rocky

The underdog story of Rocky didn’t just play out on screen—it happened behind the scenes, too. Sylvester Stallone wasn’t a big name when he wrote the screenplay, and studios were eager to buy the rights. The catch? They wanted a different lead actor.

Executives pushed for established stars like Burt Reynolds or James Caan, and Stallone was pressured to step aside. He refused, insisting that he was the only one who could play Rocky Balboa. That bold decision nearly cost him the film entirely.

In the end, his stubbornness paid off. Stallone starred in the movie, won an Academy Award for Best Picture, and launched a franchise that’s still running decades later. Sometimes sticking to your guns is the only way to win.

5. Johnny Depp — Pirates of the Caribbean

Jack Sparrow’s quirky swagger is now legendary, but during filming, Disney executives weren’t impressed. They thought Johnny Depp’s eccentric mannerisms were confusing, even asking if he was drunk on set. Talks of firing him were serious enough to make the actor nervous.

Depp defended his choices, explaining that he wanted Sparrow to feel unpredictable, like a rock star mixed with a trickster pirate. It was a huge risk, and at the time, it nearly sank his role.

Thankfully, the studio backed off, and audiences loved the performance. Depp earned an Oscar nomination and turned Pirates of the Caribbean into a billion-dollar franchise. The very thing that almost got him fired became the key to Sparrow’s magic.

6. Megan Fox — Transformers: Dark of the Moon

By the time the third Transformers movie rolled around, Megan Fox’s relationship with director Michael Bay had soured. After making controversial comments comparing him to a dictator, the atmosphere on set became explosive.

Producers and executives debated whether keeping her in the film was worth the trouble. Ultimately, the decision was made to part ways, and Fox was replaced by Rosie Huntington-Whiteley for the sequel.

Although she wasn’t fired mid-shoot, her exit was close enough to count. The sudden casting change made headlines and fueled years of gossip about on-set drama. Fox later reconciled with Bay, returning for Teenage Mutant Ninja Turtles, but her near-firing remains one of Hollywood’s most infamous feuds.

7. Tom Hardy — Mad Max: Fury Road

Filming Mad Max: Fury Road was an endurance test for everyone involved. Long days in the desert, clashing egos, and creative disputes made the production notoriously tense. Tom Hardy, in particular, butted heads with director George Miller and co-star Charlize Theron.

At several points, Hardy’s behavior was described as erratic and confrontational. Warner Bros. execs weren’t thrilled, and rumors swirled that replacing him mid-production was an option.

Despite the drama, Hardy stayed—and later admitted he was difficult during the shoot. The end result was worth it, as Fury Road became a modern classic and won multiple Oscars. Hardy’s raw intensity, which nearly got him fired, turned out to be exactly what the role demanded.

8. Shelley Duvall — The Shining

Few roles were as grueling as Shelley Duvall’s experience filming The Shining. Stanley Kubrick was infamous for his demanding directing style, and Duvall bore the brunt of it. Scenes were repeated dozens of times, pushing her to the brink of exhaustion and emotional breakdown.

At one point, producers questioned if she could even finish the role. Her mental and physical health were suffering, and talk of replacing her briefly surfaced.

Duvall persevered, and her performance became iconic for its raw, unsettling vulnerability. Though the experience left lasting scars, her work is now celebrated as one of the most haunting portrayals in horror cinema. Sometimes the most painful shoots produce unforgettable art.

9. Martin Sheen — Apocalypse Now

The making of Apocalypse Now was a nightmare of delays, budget overruns, and disasters. For Martin Sheen, it became even more personal when he suffered a near-fatal heart attack during production.

Coppola, already under immense pressure, seriously considered replacing him to keep the film alive. Insurance companies and backers were also skeptical about Sheen continuing the physically demanding role.

Incredibly, Sheen recovered and returned to set. His intense, lived-in performance gave the film a gritty realism that no replacement could have matched. Apocalypse Now went on to become a masterpiece, and Sheen’s resilience became part of the legend behind the movie.

10. Al Pacino — The Godfather

Studio executives weren’t convinced Al Pacino was the right choice for Michael Corleone. They wanted a bigger star, someone with more name recognition. Pacino’s quiet, understated approach to the character also worried them.

Throughout filming, executives floated the idea of firing him. Francis Ford Coppola fought tooth and nail to keep Pacino, believing his performance was perfect for the role.

When the restaurant assassination scene was finally shot, the doubts disappeared. Pacino’s chilling transformation from reluctant son to ruthless mob boss stunned everyone on set. That scene silenced talk of replacement and cemented Pacino’s place as one of the greatest actors of his generation.