When Detective Marconi is making the deal for medical supplies, he addresses Vaughn by name. In the next scene, Det. Marconi learns Vaughn's name from Kris (the woman cop.)
The roof mounted air conditioning unit on the Orion V high floor bus used disappears and reappears throughout the movie.
Over the course of the movie, the bus continuously changes from a New Flyer D40LF low floor to an Orion V high floor model.
When the bus crashes through the police barricade, the advertisement on the right hand side of the bus is missing.
Kris crashes her patrol car into the vehicle barricade to open up a gap to let the bus through. When the bus approaches, the patrol cars are blocking the road again in different positions with some damage to the cars. The bus crashes through the barricade anyway.
Toward the end of the movie, "Dog" calls the cell phone carrier to find out if there had been any calls made to Texas. The person on the other end of the line says yes and proceeds to give him the number which has the area code 405. 405 is an Oklahoma City/central Oklahoma area code. Since the line he calls is a land line, whose area code should be 409 for Galveston, and is not a cell phone, this is not possible.
The police lieutenant is from Louisiana. He has no jurisdiction in Texas. Also, as this is a kidnapping, it is automatically federal, which means that the FBI would have quickly taken charge.
The protagonists' plan to steal only the money that came from organized crime in the casino (because such a theft won't be reported to the police) makes no sense. The whole point of the money laundering scheme is to disguise that money into a legit income of the casino, in order to efficiently and legally protect it from such thefts. In case of a theft, the police would merely note that the stolen money is part of the casino's legit income, and they would certainly not check how exactly each stolen bank note originally entered the casino, as that would be physically impossible. Furthermore, the protagonists themselves didn't know which exact bank notes at the vault came from organized crime, but even if they did that would not help them in any way since all the money in the vault is considered a legit income of the casino.
When Cox appears to shoots the Bus driver in the head, he is standing next to the seated driver with his gun aimed 30-45 degrees downward. When the shot occurs - which we only see from the POV of the news helicopter's camera - the upper part of the windshield gets covered in blood. We later learn that not only is the Bus driver still alive, he (like the other hostages, who had seen that Vaughn was trying to protect them all along) helped Vaughn escape. And at the end we learned that there was a lot of misdirection in Vaughn's plan, in keeping with the film's recurring 'card trick' theme.
Some of the shots of the bus were flipped. This caused the doors to appear on the left hand side of the bus instead of the right. This additionally caused the text in the background objects to also be flipped.
After the tire on the bus is repaired and it departs, the back window of the low floor bus (the one with the side windows at different heights) was superimposed on the back of the high floor bus (the one with the side windows at equal heights). The superimposed image moves around as the bus pulls out.
The route number on the destination sign of the bus is the same as the fleet number of the bus.
The bus had to have been driving in one direction down the interstate for a minimum of three hours or more, since they were picked up before 4:00 AM and there was bright overhead sunshine when they finally stopped for refueling. Yet officer Kris was sent from the origin city with a gas truck after they requested fuel and was already waiting for them on the bridge.
Even though the robbery takes place in New Orleans, the bus has Alabama tags.
Toward the end of the movie, when all but one of the hostages (the driver) are released, and Vaughn escapes, the liveries/uniforms on the ambulances, EMTs, and other emergency workers state "MOBILE FIRE RESCUE". as in, Mobile, Alabama. This is incorrect chronologically as the destination of the bus was Galveston, Texas. At this point, since the bus was now in Galveston, all emergency personnel and equipment should be so indicated as being from Galveston.
I-10 doesn't go near the outskirts of Galveston. The closest point from Galveston to I-10 is at least 30 miles or so.
A mountain is visible while the bus is driving along I-10 somewhere in Louisiana. There are no mountains located on this stretch of interstate.
Towards the end a lot of petrol is poured over Vaughn by 'Dog', who is then shot by The Pope, but then Pope lights up a real cigarette right next to the place where petrol was poured. Just by the fumes alone he would have gone up in flames.
The police would not release the bus as it is packed with evidence - and they wouldn't let the lieutenant take the bus on his own, and neither Silva nor Prince would be anywhere near the bus.
Vaughn has no money, hijacks a bus, is on the national news, and suddenly gives a hospital $300,000 and no questions asked - Fact - No hospital would accept that amount of cash without a paper trail or from a person involved with Vaughn who participated in: murder/kidnapping/hijacking a public bus/cop killing/endangering the welfare of others/grand larceny/and more. The whole police force was involved and there is no way this could have gone down and the hospital would have to return the money that they would never had accepted anyway.
It turns out Vaughn's sister is the pregnant woman on the bus. How would she know to be on the bus, that was not even part of the original getaway plan. It's. stretch to think ahead of time that the getaway driver would chicken out. One could suppose Vaughn could have decided ahead of time that he was never going to get into the car, but then he also planned to take the bus hostage and get the police involved?
A blind eye could be turned to a police officer allowing a robber to get away with stealing $300.000 to pay for his daughter's operation. A police officer would never let a robber get away with keeping the other robbed $2.700.000. Unless it is the plot for a subsequent movie. In that case it would make sense to ask Al Pacino to play a part in "Heist II : dividing the loot between the daughters, sisters and probable girlfriends".