In this version of the Yoshi's Island stage, if a player's shield breaks while they are standing on one of the sloped parts at the end of the main platform, when they land they will roll off the stage, canceling the shield break stun. This allows the to immediately regain consciousness and move much sooner than intended.

There is an unused model of Luigi with blue clothing which differs quite a bit from both Luigi's and every other character's model. One interesting difference is that this costume has its shadow model integrated into the model itself, rather than having it as a separate model.

Smash Bros. Director, Masahiro Sakurai, has stated that Shigeru Miyamoto had approached him about adding Pac-Man into Super Smash Bros Brawl. Sakurai imagined Miyamoto inferring to adding Pac-Man in his original 2D form to the game, and that the idea would be "too farfetched".

Masahiro Sakurai considered making Miis playable, but decided against it. According to Sakurai, it didn't seem right at the time to have Miis punching and kicking. Miis were however added in the game's sequel six years later.

The Announcer (who also voices Crazy Hand and Master Hand) is voiced by Pat Cashman, who was the announcer for the 1990s TV series "Bill Nye, The Science Guy".

An unused subaction and corresponding animation exist for Zero Suit Samus' Plasma Whip Side-B, labelled "SpecialSItemGet". There are also two other unused throwing animations for Samus labeled as "SpecialSThrowS" and "SpecialSThrowHi".

Presumably, the attack would originally have grabbed items from a distance and slung them away as a projectile, a function that would have been unique to the character. It may have been removed due to it interfering when players were attempting to hit another player with the whip.

With enough damage, it is possible to "destroy" a Landmaster, forcing the final smash to end early. However, without hacking, it is extremely difficult to pull off.

There are multiple glitches that can occur if a character begins their Final Smash as the bridge is reforming in the stage 'Bridge of Eldin". The most notable of these is that R.O.B. will enter his final smash, Diffusion Beam, and stay in that state for the rest of the match, no matter how long. He will also remain invincible.

During the Subspace Emissary, Ike will shout "Great Aether!" before attacking the Ancient Minister in a cutscene. However, the attack he does is merely a normal Aether.

This may have been done to match the pacing of the Japanese version, where he says "ten" as he leaps into the air, and "kuu" as he swings his sword down.

An unused HUD element named "InfAdvLevel0000" was apparently intended to display a shrinking bar for 50 frames (5/6 of a second) with a "level number" in a circle. The label "pp" is even more mysterious. The black areas of the textures would have been transparent in-game.

There is an extensive amount of music that is listed within the game's data, but the tracks themselves are not present in the final version.

A black Nintendo DS Lite can be found in the boxes on one of the backgrounds in diorama mode.

The Japanese release exclusively includes a 5-minute demo of Mother 2 (known as EarthBound in West) and a 3-minute demo of "Fire Emblem: Monsho no Nazo" within the Masterpieces menu.

The only three English voice actors from Star Fox Assault's western dub to reprise their respective roles in Super Smash Bros. Brawl's Lylat Cruise conversations were:

• Jim Walker as Fox McCloud
• Alesia Glidewell as Krystal
• Mike McAuliffe as Slippy Toad

All the other characters were recasted:

• Falco Lombardi, now voiced by Dex Manley (originally Mike Madeoy)
• Wolf O'Donnell, now voiced by Jay Ward (originally Grant Goodeve)
• Peppy Hare, also now voiced by Dex Manley (originally Henry Dardenne)
• Leon Powalski, now voiced by Jim Walker (originally David Scully)
• Panther Caroso, now voiced by Eric Newsome (also originally David Scully)

This is not the case in the Japanese version of Super Smash Bros. Brawl, where literally of the Japanese voice cast from Assault, that also heavily comprised of returning voice actors from Star Fox 64, reprised their roles. More specifically, Kenji Nojima, Hisao Egawa, Kyoko Tongu, Tomohisa Aso, Teiya Ichiryusai, Mahito Ōba, Shinobu Satouchi and Tetsu Inada reprising their roles Fox, Falco, Peppy, Slippy, Krystal, Wolf, Leon and Panther respectively.

An unused graphic of the Mario icon from Super Smash Bros. Melee can be found in the game's files. The Mario icon could mean that all the icons were going to be reused from Melee, but it also could have simply been a placeholder graphic.

There is unused tile for the Stage Builder which can't be used normally. It resembles a bump, and is fully functional.

The track "Castle / Boss Fortress (Super Mario World / SMB 3)" was originally going to be in the Delfino Plaza stage, but was later moved to the Luigi's Mansion stage instead.

Masahiro Sakurai stated that the Villager from Animal Crossing was removed from Brawl during the planning stages because "he wasn't suited for battle".

In the Subspace Emissary, there were plans to include a scene where Meta Knight still had control of the Halberd, before being attacked and losing the ship to Tabuu. This scene was removed from the final game.

There's is an unused enemy called Mizzo which is never found in the Subspace emissary except during the enemy display room inside the Halberd. It appears to be an orb with arms and legs sticking out, surrounded by wind. However, a trophy exists for this enemy which will spawn randomly wherever trophies can spawn. The trophy description references this enemy's absence.