On the Mann Vs Machine upgrade station model, there's an unused section of it's texture sheet with text that reads ''Weapons of the Day: Grenades - Free Ammo with purchase - Have a nice day. - Don't die... Or, hell, do die... Whatever. - Just don't get blood on my floor."
Before release, there was a time where the Engineer's dispenser could deal damage upon exploding, where the ammount of damage dealt is determined by how much metal is inside the dispenser.
There's an unused decapitated Yeti head in the files, where opening it's model file and finding where it's textures are stored, you'll find that it was meant for a taunt from the Steam Workshop called the ''Soccer Showoff".
There exists a short made by valve that was "scrapped", but posted publicly to YouTube, by the name of "Scream Bloody Fortress". In this video, Merasmus is featured in the short with a visible mouth; the mouth they gave him is actually the Engineer's mouth, spliced off and applied to Merasmus' model.
The Pyros flamethrower hose use to connect to the gas tank on their back before the game shipped.
Despite the Rocket Launcher in "Trailer 2" for TF2 having only 1 rocket visible poking out of the front of the gun, it still had a clip of 4 rockets. In the trailer, there's a brief moment where you can see a Soldier shooting two rockets in a row at the Scout, during the Scouts segment of the trailer.
The BLU Scout use to have team coloured pants, but somehow ended up with RED's. This mistake happened earlier in development as well, but with RED having BLU's pants.
Despite popular belief, the Dynamite Pack shown in "Trailer 2" is not a weapon like the Stickybomb Launcher or Bottle is - it's a Grenade; You pressed and held a button to prime either your Primary or Secondary Grenades, then release the button to throw the grenades. To balance Grenades, Valve made it so that the class had to lower/holster their weapons in order to throw their grenades, leaving the user vulnerable as they can't use their weapons while priming a grenade.
The Nailgun from the beta likely had pooled ammo, in the way the Flamethrower and Minigun have pooled ammo, given the fact it's weapon model doesn't have any bones to allow the clip to be pulled off.
Spawnrooms use to have "Spawn Turrets" that would pop out from the ceiling and shoot at enemies who entered into the wrong spawn. This was replaced by the little "No Entry" symbol that stops enemies from entering your spawn.
The reason the "Spycrab animation bug" exists is due to the Disguise Kit's crouch animations using the aim animations meant for the Knife from the Beta.
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