A recent update on Chennai consular website indicates that new courier delivery service is available for U.S. passports through VFS courier services. Henceforth all American Citizens opting for courier delivery should obtain a demand draft in favor of “VFS Global Services Pvt. Ltd” for INR 166 per passport. S/he should carry the demand draft along with a completed courier slip for the appointment available here for respective consulate / embassy. The facility is available for all U.S. consulates / embassy in India. The applications without demand draft and completed VFS courier slip at Mumbai consulate will be treated as collection of passport in-person from the ACS Unit at the consulate.
Alternatively American citizens may collect the passport in person from the respective American Citizen Services unit on Monday to Friday except the last Wednesday of the every month and on the respective consular holidays. The specified hours for collecting the U.S. passport is available on respective consulate / embassy website.