Honda Unveils the Most Rugged Passport Ever: 2026 Passport TrailSport Hits Production in Alabama

Honda’s Alabama Auto Plant has begun production of the 2026 Honda Passport and rugged Passport TrailSport, the brand’s most off-road capable SUV yet. Built exclusively in Lincoln, Alabama, the SUV features a 3.5L DOHC V-6 engine and a 10-speed automatic transmission. The TrailSport model includes steel skid plates, heavy-duty recovery hooks, and a 5,000-pound towing capacity. Honda’s light truck platform enhances rigidity and off-road performance.

New manufacturing advancements improve efficiency and quality. The plant has produced over 6.5 million vehicles since 2001. Honda continues expanding its vehicle lineup, including hybrids and EVs. For more details, visit hondaalabama.com.

Honda Unveils the Most Rugged Passport Ever: 2026 Passport TrailSport Hits Production in Alabama

Honda’s Alabama Auto Plant (AAP) has officially commenced production of the all-new 2026 Honda Passport and its rugged TrailSport variant, marking a significant milestone as the company’s most off-road capable SUV to date. Manufactured exclusively in Lincoln, Alabama, by a dedicated team of more than 4,500 associates, the fourth-generation Passport lineup is engineered to deliver both exceptional off-road capability and smooth on-road performance. The TrailSport model, designed for adventure, features a 3.5-liter DOHC V-6 engine—built at the same facility—and the Passport’s first-ever 10-speed automatic transmission, ensuring enhanced performance across various terrains.

According to Lamar Whitaker, Plant Leader at AAP, the associates have demonstrated remarkable dedication in bringing Honda’s most rugged SUV to life. Available in three trims—RTL, TrailSport, and TrailSport Elite—the 2026 Passport is built on Honda’s light truck architecture, first introduced with the Honda Pilot two years ago, providing enhanced structural rigidity and off-road capability. The base Passport RTL starts at $44,750, excluding a $1,450 destination charge.

Honda’s seamless collaboration between R&D, manufacturing, and purchasing teams has facilitated the implementation of new production technologies that improve vehicle quality and streamline assembly. The introduction of a flush mount parking system utilizes an advanced ultra-sonic welding tool for efficient sensor installation, while the adoption of a front-end module system allows for improved ergonomics and easier engine component installation.

The TrailSport models come equipped with thick steel skid plates, designed to withstand heavy impacts, and heavy-duty recovery hooks rated at twice the vehicle’s gross weight rating, enhancing both safety and off-road capability. Additionally, a standard trailer hitch enables the TrailSport to tow up to 5,000 pounds while integrating rear recovery points for added durability. To further improve efficiency and quality, AAP has incorporated lift-assist devices for assembling key components such as the steel hood and reinforced second-row seats.

Honda’s Alabama facility has been producing light trucks for over two decades, with operations beginning in 2001. With an annual capacity of 340,000 vehicles, AAP has manufactured more than 6.5 million vehicles and V6 engines, making it the exclusive production site for Honda’s Pilot, Passport, Odyssey, and Ridgeline models, including all TrailSport variants. The plant plays a crucial role in Honda’s North American manufacturing operations, ensuring high-quality production standards and innovative assembly techniques.

Over the years, AAP has integrated advanced manufacturing processes, including lift-assist devices and precision welding technologies, to enhance efficiency and ergonomics. The facility’s commitment to sustainability and continuous improvement has contributed to Honda’s reputation for reliability and performance, reinforcing its leadership in the automotive industry.

Honda continues to expand its diverse vehicle lineup, offering everything from the Civic and Accord sedans to SUVs like the CR-V, Passport, and Pilot, along with an increasing focus on electrification. The brand’s hybrid and all-electric models, such as the Prologue and CR-V e:FCEV, reflect its commitment to sustainability. With over 40 years of manufacturing experience in North America, Honda remains dedicated to producing high-quality, innovative vehicles, with nearly all Honda models sold in the U.S. in 2024 being manufactured in North America—two-thirds of them built in the United States using locally sourced components.