2006 Saturn Ion Problems: 5 Known Issues
2006 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated November 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2006 Saturn Ion has 5 documented known issues, with 2 rated critical. The most serious are Ignition Switch Can Unexpectedly Shut Off Engine (GM Defect Recall) and Sudden Loss of Electric Power Steering Assist ($500-$1,200 repair). Across all issues with published estimates, repair costs range from $150 to $1,200. DIY maintenance guides at au7o.io.
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All 5 Known Issues
NHTSA Recalls12 recalls
ELECTRICAL SYSTEM:IGNITION
General Motors LLC (GM) is recalling certain model year 2005-2010 Chevrolet Cobalt, 2006-2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2003-2007 Saturn Ion, and 2007-2010 Saturn Sky vehicles. In the affected vehicles, the key can be removed from the ignition when the ignition is not in the "Off" position.
STEERING:ELECTRIC POWER ASSIST SYSTEM
General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.
ELECTRICAL SYSTEM:IGNITION:SWITCH
UCI-FRAM Group is recalling certain LS1328 ignition Switches sold as Wells LS1328, Duralast LS1328, Airtex 1S6097, and Carquest 53-27479, and LS1497 Ignition Switches sold as Wells LS1497, Duralast LS1497, Airtex 1S10961, and Carquest 53-27967, for use on various General Motors model and model year vehicles during repair and replacement of the original ignition switch. The weight on the key ring and/or road conditions or some other jarring event may cause the affected ignition switches to move out of the run position, turning off the engine and disabling the air bags.
AIR BAGS
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2006 CHEVROLET COBALT AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA AND NEVADA; AND MODEL YEAR 2007 CHEVROLET COBALT, PONTIAC G5 AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA, CALIFORNIA, FLORIDA, NEVADA AND TEXAS. THE PLASTIC SUPPLY OR RETURN PORT ON THE MODULAR RESERVOIR ASSEMBLY MAY CRACK. IF EITHER OF THESE PORTS DEVELOPS A CRACK, FUEL WILL LEAK FROM THE AREA. IF THE CRACK BECOMES LARGE ENOUGH, FUEL MAY BE OBSERVED DRIPPING ONTO THE GROUND AND VEHICLE PERFORMANCE MAY BE AFFECTED.
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Frequently Asked Questions
What are the most common Saturn Ion problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2006 Saturn Ion has 5 documented issues. Documented issues include: Ignition Switch Can Unexpectedly Shut Off Engine (GM Defect Recall), Sudden Loss of Electric Power Steering Assist, Key Stuck in Ignition / Worn Lock Cylinder. Of these, 2 are rated critical and should be addressed promptly.
Is the Saturn Ion reliable?
The 2006 Saturn Ion has 5 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: Ignition Switch Can Unexpectedly Shut Off Engine (GM Defect Recall) and Sudden Loss of Electric Power Steering Assist. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Saturn Ion problems?
Repair costs for known Saturn Ion issues range from $150 to $1,200, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2003-2007 Saturn Ion Ignition Switch Can Unexpectedly Shut Off Engine (GM Defect Recall)?
The ignition switch detent torque is too low, so weight on the key ring, road vibration, or a knee bump can move the switch out of the 'run' position while driving. This shuts off the engine and disables power steering, power brakes, and critically the airbags, which will not dep… Severity: high.
What is the 2003-2007 Saturn Ion Sudden Loss of Electric Power Steering Assist?
The electric power steering (EPS) motor can suddenly lose assist at any time while driving, often mid-turn or at low speed, due to brush debris and oily contamination disrupting the EPS motor. Steering remains mechanically connected but requires much greater effort, especially du… Repairs typically run $500-$1,200. Severity: high.
What is the 2003-2007 Saturn Ion Key Stuck in Ignition / Worn Lock Cylinder?
Separate from the safety recall, Ion owners frequently report the key sticking in the ignition or refusing to turn fully off, often getting trapped in the ACC position. This stems from a worn ignition lock cylinder, worn key teeth, or a faulty Brake-Transmission Shift Interlock (… Repairs typically run $150-$400. Severity: medium.
What is the 2003-2007 Saturn Ion Inaccurate or Erratic Fuel Gauge (Fuel Level Sensor)?
The fuel level sender inside the tank develops contaminated or worn contacts, sending erratic resistance signals to the gauge. Owners see the needle misread, drop or stick especially below a quarter tank, give false low-fuel warnings, or read empty when fuel remains. Disconnectin… Repairs typically run $200-$500. Severity: medium.
What is the 2003-2007 Saturn Ion Interior Door Panel and Trim Rattles?
The Ion's interior is prone to rattles and squeaks, most commonly from the door panels. A black plastic reinforcement strip glued along the top of the door panel can separate, and loose window glass/regulator components produce a glass-on-metal rattle over bumps. The glovebox doo… Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.