From indian embassy site:
ISSUE OF NEW PASSPORT
Application for a new passport can be made six months before date of expiry or within one year of the expiry of the passport.
Requirements for issuing new passport are:
(a) Duly completed application form filled in BLOCK LETTERS in expanded form using black/blue ink only (see Application Form for an Indian Passport)
(b) Four latest identical passport size photographs depicting the applicant’s facial features against a light background;
(c) In cases, where the passport has already expired beyond a period of one year, the Applicant should submit an affidavit (see Annexure) and may have to appear personally before the Consular Officer;
(d) Two proofs of residence/mailing address in USA (photocopy of Driving license/ Lease agreement/ Utility Bills etc.);
(e) Alien Status (photocopy of US Visa/Green Card/ Work authorization card);
(f) Current Passport;
(g) Proper Fee (see fee schedule for details)
(h) Applicants for a new passport or additional booklet are required to submit a photocopy of marriage certificate, in case, the name of their spouse have not been included in their respective passports.
If the application is found to be in order and no prior reference is required to be made to the original Passport Issuing Authority, a new passport will be issued within 5 working/business days from the date of receipt of the application