Jessica Biel (Erin Hardesty), Jonathan Tucker (Morgan), Andrew Bryniarski (Thomas Hewitt / Leatherface), Erica Leerhsen (Pepper), Eric Balfour (Kemper), Mike Vogel (Andy), R. Lee Ermey (Sheriff Hoyt) more..., David Dorfman (Jedidiah), Lauren German (The Hitchhiker), Heather Kafka (Henrietta), Terrence Evans (Monty Hewitt), Marietta Marich (Luda Mae Hewitt), John Larroquette (Narrator (voice)), Kathy Lamkin (Tea Lady in Trailer), Brad Leland (Big Rig Bob), Mamie Meek (Clerk), Harry Jay Knowles (Victim On a Silver Platter (uncredited))

Scott Kosar (Screenplay), Jeffrey Allard (Executive Producer), Michael Bay (Producer), Ted Field (Executive Producer), Mike Fleiss (Producer), Andrew Form (Executive Producer), Steve Jablonsky (Original Music Composer) more..., Daniel Pearl (Director of Photography), Glen Scantlebury (Editor), Bradley Fuller (Executive Producer), Bobbie Mannix (Costume Design), Greg Blair (Production Design), Scott Gallagher (Art Direction), Randy Huke (Set Decoration), Kathy Kiatta (Costume Supervisor), Matthew Cohan (Associate Producer), Joe Dishner (Co-Producer), Kim Henkel (Co-Producer), Tobe Hooper (Co-Producer), Pat Sandston (Associate Producer), Debbie Cortez Haber (Art Department Coordinator), Joe McCusker (Construction Coordinator), Shane Patrick (Leadman), Logan Cooper (Location Scout), Kara Sutherlin (Standby Painter), Peter Simonite (Additional Photography), Jeffery J. Tufano (Camera Operator), James Marks (Camera Technician), Theda Cunningham (First Assistant Camera), Van Redin (Still Photographer), Kelly Nelson (Key Hair Stylist), Jay Flood (Additional Music), Steve Allen (Carpenter), Scott Stoddard (Makeup Effects), Russell E. Scott (Picture Car Coordinator), Sara Mineo (Post Production Assistant), Tami Goldman (Post Production Supervisor), Corissa Smith (Scenic Artist), John Arszyla (Set Medic), Anthony Cecere (Stunt Coordinator) and others.