When Tommy is kicked in the face while fighting robo Tommy, his Dino Thunder helmet ends up broken on the wrong side, not matching the impact against the wall.
In the shot after Lord Draven picks up one of his arrows and commands the robot army to attack, his arrow and their busted package (that were on the ground) disappear.
The end fight with the megazords just doesn't work because two out of the three don't exist anymore, the dino megazord became the thunder megazord in 1994 and the thundersaurus megazord was destroyed in 2004.
Kat inserted a pointed metal rod into her Turbo Morpher instead of the Turbo Key.
When telling the Ninja Steel Rangers, "You can't hide forever, Rangers," Lord Draven suddenly slips into a New Zealand accent.
When Madame Odius asks Draven how the robotic technology she supplied is working, Draven informs her that the robotic Tommy has already captured 7 Rangers. He then tells the robot Tommy to, "Show her." Robot Tommy then drops his holographic outer shell to show off that he is a robot, but that is not what Draven was telling him to show Odius. Draven was telling robot Tommy to show Odius the Rangers he'd captured. Since Odius supplied Draven with the robot technology, she'd already be well aware of what the fake Tommy's base form looked like. Robot Tommy dropping his holographic shell was done for the benefit of the hidden Rangers who were watching and the viewing audience, not for any sort of story reason.
The veteran Rangers use a "Ranger reveal" ability that none of them previously had.
What became of JJ, Tommy son? Tommy was the parent in charge at home right before his abduction (and right before taking JJ to school). Time would have passed to make a robot copy and station it at the house, giving the abandoned son time enough to go somewhere else, but it's a dangling story point never followed (and Tommy, absorbed in fighting, never worries over him).
Tommy uses the Black Dino Thunder Ranger powers to turn invisible, escape Draven's fortress, and defeat a squad of his foot soldiers. In Power Rangers DinoThunder (2004) it was established that the Dino Thunder Rangers can only use their unique powers, such as Tommy's invisibility, while unmorphed. Tommy was also seen running at superhuman speed as the Black Dino Thunder Ranger powers, which was not part of that Ranger's power set (the Red Ranger that season had super speed as his unique power, but, again, could not use it while morphed).
The morpher that Antonio uses is not his Samurai Morpher, but rather a Samuraizer.
When morphed, Trent's costume has a white neck when it should be black.
After the Ninja Steel Rangers volunteer to find Lord Draven's chest to prevent him from using the remaining two arrows, Tommy tells the others that he'll lead them into Draven's dungeon to rescue the other captive Rangers. As they all head off to their designated tasks, Tommy says, "Wes, your team's with me." They'd already established that he'd be leading Wes's team to the dungeon a few seconds earlier.
After the captive Rangers have been freed, Trent specifically thanks Tommy for rescuing them, completely ignoring Wes, Koda, and Gemma's contributions to their rescue.