Role: Trini Kwan (originally "Trini Crystal") / Mighty Morphin Yellow How close was she? Audri filmed the pilot before the show got retooled and she was let go. Why she was let go: She decided not to take the risk and drop everything for the show.
Trivia: If you look closely at the final version of Day of the Dumpster, you'll see a shot of Audri's Trini while everyone is outside the Command Center.
Role: Adam Park / Mighty Morphin Black How close was he? He had gotten far enough in the audition process to actually meet the actors who made the show. Why he was turned down: According to reports, there were multiple locations for auditions, and the casting director didn't like the finalists from the other locations.
Role: Chad Lee / Lightspeed Blue How close was he? Unknown, but he won the role of the Quantum Ranger the following year. Why was he turned down? According to Dan, he was "too intense" for the role.
Trivia: Dan actually did portray Adam during the live show, Mighty Morphin Power Rangers World Tour Live on Stage. In fact, he pretty much became a regular suit performer for any live appearance, and wore several different suits over several years.
Dan also auditioned for yet ANOTHER character that he's never really talked about.
Role: Dulcea How close was she: Mariska filmed several scenes. However, according to various cast members, the directer wasn't very professional and a lot of things were changed, scrapped and re-filmed. Why she was let go: Her scenes were some of the ones that weren't liked, so they brought back the original actress, who had to drop out prior to shooting.
Role: Eric Myers / Quantum Ranger How close was he? He was up against Dan Southworth, how close do you think he was? Why he was turned down? He thinks it's because he was too "egotistical," but that may not be the official reason.
Trivia: Rick may have auditioned for an earlier season, as well.
Role: Alyssa Enrile / Wild Force White How close was she: Apparently she actually won the role. Why she was let go: According to reports, Koichi Sakamoto demanded a character that his wife could double for, thus she was given the role of Kendall instead.
Trivia: Fox Kids actually released a promo with Sandra's voice over the White Ranger, but no live action footage seems to have been filmed while she was in the role.
Role: Tori Hanson / Blue Wind Ranger How close was she? Close enough that the people in charge remembered her. Why she was turned down: She just didn't fit the role, but was brought back to audition for Kira the following year. And won.
Role: "Kayla" / RPM Yellow How close was she: Obviously she lost the role before the name changed. Why she was turned down: It's not known if she did indeed win the role, or it was just wishful thinking on her and/or her agent's part.