Honda upgrades production with advanced processes for 2026 Passport models

Honda’s Alabama Auto Plant (AAP) has officially begun production of the all-new 2026 Honda Passport and Passport TrailSport, incorporating cutting-edge manufacturing processes that are reshaping the way vehicles are built. By integrating new tools, refining assembly methods, and prioritising ergonomics, the company says it is enhancing efficiency, improving vehicle quality, and making the production process easier for associates.

“The deep collaboration of the Honda R&D, manufacturing, and purchasing teams enabled us to create a high-quality Honda Passport that also will be easier for our associates to build,” said Mike Smith, senior staff engineer at AAP and the Engineering Project Leader for Passport.

These advancements stem from Honda’s “One Floor” approach, which unites R&D, manufacturing, and purchasing teams from the earliest stages of development. This collaborative model has led to significant innovations, with refinements to vehicle design and the introduction of new processes that optimize quality and efficiency while simplifying assembly.

Advancements in production processes
One of the significant improvements in the production process comes in the way the flush mount parking sensor system is installed. For the first time, AAP associates are using ultrasonic welders to seamlessly integrate four sensors into the front bumper. To enhance efficiency and versatility, Honda worked with a supplier to develop a custom cradle that allows the base equipment to adapt to multiple vehicle models. This ‘first-in-Honda’ tool eliminates the need for separate machines, reducing production costs and maximising floor space.

In another major shift, the Front-End Module (FEM) is being used for the first time in Passport assembly. This approach enables associates to step into the front of the vehicle rather than reaching over it, significantly improving ergonomics and making the installation of key engine room components more efficient. Honda says the result is a streamlined process that not only reduces strain on workers but also enhances overall build quality.

As Honda pushes forward with the off-road capabilities of its TrailSport models, production teams have adapted new processes to install heavy-duty skid plates that protect critical components such as the oil pan, transmission, and fuel tank. These skid plates are built to withstand significant impacts, capable of supporting the full weight of the vehicle when hitting a rock. Attention to detail extends to the newly integrated recovery points, which are now a standard feature on the Passport TrailSport. Designed to handle twice the Gross Vehicle Weight Rating (GVWR), these cast-iron recovery points are powder-coated for corrosion resistance and engineered to break away in the event of a front collision. To ensure precise and consistent installation, associates now use DC torque tools instead of manual or pneumatic alternatives, improving both efficiency and accuracy.

The trailer hitch installation process has also seen notable improvements. With towing capacity increased to 5,000lbs, AAP associates needed to develop a more substantial hitch, requiring two additional bolts compared to the Pilot’s hitch. To simplify this process and maintain accuracy, Honda introduced a semi-autonomous lift assist system, which allows a single operator to position and install the hitch with greater precision.

To accommodate the introduction of heavier components, Honda has implemented several lift assist devices at AAP. The transition to a steel hood, an essential feature in the rugged redesign of the Passport, necessitated the use of lift assists in welding, painting, and final assembly to ensure smooth handling. Similarly, the installation of the second-row seat, which now includes a steel-reinforced support structure for improved crash protection, required an upgraded lift assist system to manage the 100+ lb seat structure with greater ease and accuracy.

Attention to detail has been a priority throughout the production process, as seen in refinements to the matte finish of the exterior rear cargo garnishes. Late in development, AAP associates identified potential durability concerns related to scratches from outdoor gear such as skis and fishing poles. Adjustments were made before mass production, ensuring the finish meets Honda’s high-quality standards while maintaining the rugged aesthetic customers expect.

Powertrain and final assembly
The 2026 Honda Passport is powered by a 3.5-litre V6 engine, producing 285 horsepower and 262 lb.-ft. of torque. This engine is built at the AAP engine plant, while the new 10-speed automatic transmission is manufactured at Honda’s Georgia Transmission Plant.

Honda Alabama Auto Plant
Since opening in 2001, Honda’s Alabama Auto Plant has built more than 6m vehicles and nearly 6mV6 engines, cementing its role as a key player in Honda’s North American production network. The facility employs 4,500 associates and boasts an annual production capacity of 340,000 light trucks, including the Honda Pilot, Passport, Odyssey, and Ridgeline.