The sound effects used for Ben's bike were a combination of a lion roar, a Bengal tiger growling and a jet engine whistle.
According to Tim Schafer, Full Throttle originally would have featured a sequence where Ben undergoes a peyote-induced hallucinogenic trip. This was eventually ejected from the game, because the developers couldn't get it to "work out" with the publishing. The concept eventually became the basis of "Psychonauts".
There was originally two attempts in making a sequel for this game. The first attempt was back in spring 2000, LucasArts began production of a direct sequel titled "Full Throttle: Payback". Because Tim Schafer had already left the company at the time, Larry Ahern, who was involved in the original game's development, was appointed the project lead and Bill Tiller, the art director. The story would have focused on Ben's efforts to foil a plan by a "large corporation" and the local governor to replace all paved highways with hover pads, robbing the bikers and truckers of their traditional ground. In the first half of the game, Ben would have prevented an assassination attempt on Father Torque, who now leads the anti-hovercraft rally, then team up with a "persistent undercover female reporter" to bring down the villainous governor. In Tiller's opinion, Payback "was going to capture the feel of the first game yet expand upon the milieu". At the early stages, the project received positive feedback from other LucasArts employees but according to Tiller, it eventually fell apart because of disagreements on the game style between the production team and "a particularly influential person" within the management, which led to a series of "mistakes". The production ceased in November 2000, when 25% of the levels and about 40% of the pre-production art were complete. LucasArts never released an official statement regarding the game cancellation. Both Ahern and Tiller left LucasArts in 2001, after Payback was canceled. In mid-2002, LucasArts announced Full Throttle: Hell on Wheels for Windows and, for the first time in the series, PlayStation 2 and Xbox. The game was to be an action-adventure, with more emphasis on action and fighting than adventure, because the designers wanted the game to feel more physical than the first. Hell on Wheels would have been set in El Nada, Ben's "old stomping ground", whose roads have been mysteriously destroyed. Ben believes that one of the new gangs introduced in the game, the Hound Dogs, are behind this but soon discovers a more sinister and murderous plot. Together with Father Torque and Maureen, he would have thwarted the unnamed villain's plan and protected "the freedom of the open road". Sean Clark was named the project lead of Hell on Wheels and the development progressed smoothly until late 2003, when it was abruptly canceled. Just months prior to that, at E3 2003, a playable demo was shown and a teaser trailer was released by LucasArts. Simon Jeffery (then president of LucasArts) said that "We do not want to disappoint the many fans of Full Throttle, and hope everyone can understand how committed we are to delivering the best-quality gaming experience that we possibly can" in the official press release. Critics cited poor graphics compared to other 3D action adventures of the time and Tim Schafer's lack of involvement in the project as possible reasons for its cancellation. Additionally, Roy Conrad, the original voice actor for Ben, died in 2002. Critics considered development of new sequels to Full Throttle unlikely. LucasArts' interest shifted away from the adventure genre in later years, and failure to develop two sequels presumably hindered the possibility of a third. Also, nearly all developers who were involved with the original Full Throttle in 1995 had since left LucasArts. LucasArts ceased all internal development in 2013, shortly after their parent company Lucasfilm was purchased by The Walt Disney Company. In a 2017 interview discussing the work on the remaster version, Schafer said that he feels that the story of Full Throttle was essentially complete with the game, and does not envision creating a sequel himself.
According to Tim Schafer, Maureen had a wealthy twin sister named Tina in the original story, and the two were supposed to have a "prince-and-pauper" subplot worked into the game where they secretly switched identities. Ultimately, Tina was dropped from the storyline, and Maureen remained. Both characters were named after real twin sisters Schafer was friends with in college.
Tim Schafer claims it took the writers a whole day to come up with the name "Pre-regulation Destroyer-Class Solid Fuel Recoil-Booster" for the bike accessory that figures into one of the game's puzzles.