All-New 2026 Honda Passport Production Starts In Alabama 

More than 4,500 Honda associates at the Honda Alabama Auto Plant (AAP) in Lincoln, Alabama recently celebrated the start of production of the all-new 2026 Honda Passport. The fourth-generation lineup includes the Passport TrailSport, the most off-road capable Honda SUV ever, along with the first-ever Passport TrailSport Elite trim.   The three-trim lineup also includes the base RTL trim, priced starting from $46,200 with destination.

We had our first chance to check out the Passport TrailSport recently at the 2025 North Texas Auto Expo:

The Passport is equipped with a 3.5-liter DOHC V-6 along with the Passport's first 10-speed automatic transmission. For 2026, Honda says Passport offers a number of new rugged features to enhance the off-road experience.

"Honda associates in Alabama worked with ingenuity and determination to bring to market the most rugged Honda SUV ever for our customers, the all-new 2026 Honda Passport," said Lamar Whitaker, plant leader of the Alabama Auto Plant.

The Passport is based on Honda's light truck architecture that launched two years ago on the new Honda Pilot. The automaker says it's an extremely rigid platform that was engineered for off-road capabilities.

Honda says building the new Passport included new production technologies and processes. 

• AAP associates worked closely with the Ohio-based R&D team based on the unique Honda "One Floor" approach of having R&D, manufacturing and purchasing associates collaborating from the earliest stages of product creation. Honda says that for the first time, this involved members of the Alabama New Model Team being based at the North American Automotive Development Center (ADC) in Ohio. The automaker says the collaboration resulted in refinements to the vehicle design and creation of new processes and tools to achieve higher quality and efficiency, while also making Passport easier for associates to build.
• Honda says AAP associates applied a new tool for use with the flush mount parking system, equipment that installs four sensors into the front bumper that are used to alert the driver when approaching an object. These sensors are mounted "flush" with the surface of the bumper using ultra-sonic welders. AAP associates worked with a supplier to design a new cradle to fit in the base equipment – a new, first-in-Honda tool – to give the equipment new-found flexibility to efficiently work on multiple models, eliminating the need for multiple pieces of equipment and saving floor space.
• In the new generation, Passport adopts the front-end module (FEM) for the first time, an approach to assembly that enables associates to step into the front of the vehicle to install key components inside the engine room, rather than reaching over the front end of the vehicle. Honda says this results in a major improvement in ergonomics for associates, reducing the number of production processes, while promoting high build quality.
• AAP associates install two thick steel skid plates to protect the oil pan, transmission and gas tank of Passport TrailSport and TrailSport Elite, capable of supporting the entire weight of the vehicle crashing down on a rock while minimizing the collection of debris like sand, gravel, mud and snow.
• For the first time ever on a Honda light truck, Passport TrailSport models are equipped with heavy-duty front and rear recovery points rated at twice the Gross Vehicle Weight Rating (GVWR) of Passport. Constructed of cast-iron, the bright orange closed loop front recovery points are powder coated to resist corrosion and engineered to break away in the event of a front collision. Honda says this patented design is a world's first and enables the Passport to target top of class safety ratings. Due to the critical role they play, the recovery hooks are installed with DC torque tools rather than manual or pneumatic tools, which helps associates install the recovery hooks to desired specifications while making the process easier for associates.
• A trailer hitch is now standard on both Passport TrailSport models which can tow as much as 5,000 pounds, more than enough for most boats, campers or "toy" trailers used by Honda customers. Installed by AAP associates, the new trailer hitch also integrates the two rear recovery points helps protect the rear fascia from off-road damage. The trailer hitch on Passport is more substantial with two additional bolts compared to the hitch on the Pilot, requiring a new piece of equipment that enables associates to use a single lift assist arm to guide the semi-autonomous process that is easier and achieves precise installation of the hitch.
• A number of lift assist devices were added at AAP to make processes easier for associates and to achieve high quality. A new steel hood introduced as part of the rugged capability of Passport, required the addition of lift assist devices in weld, paint and assembly to help AAP associates to handle and install the hood. The design of the new second-row seat includes a steel-reinforced support structure that plays a role in Passport's crash protection, requiring a stronger lift assist device to make it easier to achieve precise installation of the more than 100 lb. seat structure.
• A key component of the Rugged design theme is the matte finish of exterior garnishes on the exterior of the rear cargo area that enables customers to lean skis, fishing poles and other equipment against Passport without scratching the surface. Late in the development process prior to mass production, AAP associates identified the need to adjust the finish on the garnishes to ensure quality for the customer by preventing scratches.
• The AAP engine plant builds the 3.5-liter, 6-cylinder engine that powers Passport, producing 285 horsepower and 262 lb.-ft. of torque. The 10-speed automatic transmission – new to Passport – is made at the Honda Transmission Plant in Georgia.

Photo Credit: Honda.