2005 Saturn ION Saturn ION 2005

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2005 Saturn ION repairs by problem area

Engine (42%)

Transmission and Drivetrain (0%)

Brakes and Traction Control (4%)

Suspension and Steering (35%)

Electrical and Air Conditioning (13%)

Paint, Rust, Leaks, Rattles, and Trim (0%)

Other (6%)

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Chart based on 69 repairs.
See TSBs and recalls for the 2005 Saturn ION.

2005 Saturn ION suspension repair cost distribution

$2500+ (0%)

$1000 - $2499 (4%)

$500 - $999 (26%)

$100 - $499 (52%)

< $100 (17%)

Chart based on 23 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2007 Saturn ION

Engine not specified

99000 mi

US $400
replaced control arm bushings; full alignment 
102000 mi

US $270
Fuel pump replaced because it was spraying fuel under car. GM issued a partial recall for this safety issue, but not for cars in my state! After difficulty obtaining new pump (2 weeks, 2 vendors), successfully completed repair myself. 

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2007 Saturn ION 4dr Sedan

355-horsepower 5.4L V8 4-speed automatic FWD

43000 mi

US $205
right front lower bushing replaced & appears to be quite common repair on Saturns. looks like I can plan on replacing L & R around the next 35,000 miles or so. crumby engineering of suspension. 
54000 mi

US $185
Diagnosis P0446 Evap Vent Solenoid sticking. Installed new updated solenoid with wiring harness. 
62700 mi recall on ignition switch 
68000 mi

US $150
front arm bushings replaced - 2nd time since I have owned the car. First time was around 38,000 miles (car was out of warranty 1st time) 
68000 mi Air bag fault light, dealer said the module needed replacement. Only happens when cold outside. Decided not to repair due to cost at this time ($750). Will research further. 
73000 mi

US $75
Switch unit for front inside lights and sun roof control replaced, light switch had come apart. 
79000 mi

US $600
R/R front wheel bearings. 
88300 mi

US $50
Evaporator/Condenser unit was leaking water into te cabin. These were replaced. I removed the carpet and seats to trouble shoot the problem and I ended up finishing that part of the job. While I was trouble shooting the A/C water leak issue and checking that the water tubes for the sunroof were functioning the sunroof broke. 
97000 mi

US $600
Shift solenoid 1-2 was bad, R/R all solenoids, fluid, filter, CV shafts/joints, antifreeze, rotate tires. 
97000 mi

US $50
Code for Accelerator Pedal sensor came up as an engine light. Looked up troublshooting in sequence online (AllDataDIY), tested wiring to pedal sensor, tested sensor, found bad connection in harness connector under dash. Repaired. 
14880 mi

C $543
Sun roof drains were clogged and caused small leakage / drip in interior. But water supposedly also accumulated in A or B pillar causing front driver door switch to be corroded/ malfunction - in turn causing problems with the interior lighting. 
34100 mi

C $200
Replaced failed intermediate shaft to eliminate annoying ratting noise from under dash. This is a known failure with Ions and Cobalts Clunking metallic noise on bumpy roads. Vertical bushings in lower control arms have split replaced with Moog solid bushings/ and new control arm - as this was less work since I do not have a press. 
34100 mi

C $15
Replaced 2 bushings (on subframe) for stabilizer link in attempt to eliminate front end rattle evident on wavy pavement or slight bumps. Repair improved situation . 
35960 mi

C $200
Check engine code P0172 rich fuel limit reached, fuel pump over pressure at 90 psig. Put in complete new pump/float/ filter assembly from Rockauto for $200. Pressure is now 60 psig. Code eliminated and adaptive memory in normal range. 
38440 mi Recall - electric steering assist replaced by under recall. It was getting very erratic (loss of assist) but dashboard light never came on as described in GM recall notice. 
90980 mi

C $800
wheel bearing/hub assembly (right front) and rear coil springs. 
92560 mi

C $350
fuel line leak, rotted out in several places 
117800 mi

C $300
Stabiliser bar linkage had play and needed to be replaced as it was causing vibration during braking 
122540 mi

C $1200
rear shocks plus some brake work and new tires 
52000 mi

US $167
control arm bushing replaced. 
15000 mi Transmission pressure control solenoid valve replaced under warranty. 
17500 mi Power window on passenger side rear door failed. New regulator installed. 
23000 mi

US $40
Electric power steering stopped working at low speeds. Fixed at no charge (new motor and codes) under TSB. 
45000 mi Coolant lines leaking; dealer replaced lines and replaced transmission pan gasket Automatic transmission solenoid faulty, preventing key from being released from ignition when car was in Park position. New solenoid installed under Saturn technical service bulletin. 
49000 mi

US $1200
Passenger side front wheel bearing needed replacement. 
9000 mi

US $60
Right rear brakes were squealing. Were not properly assembled and lubricated during manufacture. 
10000 mi Squeak coming from right front when going over modest bumps on road at 20 mph or greater. 
11000 mi Radio memory selection buttons did not work. Hit the side of the radio fixture with open hand a couple of times and radio memory buttons started working. Intermittent in radio connections, but problem has not re-appeared after more than a week. 
12000 mi

US $9
Brake pedal was making a squeaking noise when depressed. Used spray lubricant on pedal arm mechanism inside car. Squeak went away and has not returned a week later. 
15000 mi Squeaking noise coming from engine compartment. Only present for about 15 minutes when car cold and first started up.  
23000 mi Left lower control arm was noisy. Defective part was replaced under OEM Warranty. Rear right brakes were very squeaky when brake pedal pushed down. Also when parking brake engaged. Brakes were disassembled and parts were lubricated. From a previous front suspension repair, technician did not re-install heat shield properly, and it was making a loud rattling noise. Technician found the improperly installed shield, and re-mounted properly. No further noises. 

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2007 Saturn ION 4dr Sedan

266-horsepower 3.5L V6 5-speed manual FWD

8000 mi

US $33
Clutch pedal feels like it catches on something at the release when synchronizing. Continues to get worse as time goes by. 
26000 mi Turning the wheel there was some grinding noise. Turns out there were rocks in the Strut Adjuster. I think that is correct. Promblem resolved  
52000 mi

US $52
Don't have the work order so unable to explain. Emissions and something burned out. Will try to find out and explain 
89000 mi Valve # 3 was replaced - problem was fixed by power train warranty. 
126500 mi

US $800
needed a new fuel pump - will make another trip to repair fuel gage - not working - faulty pump 
142000 mi unrepaired problem with the front end 
24800 mi Paint on rear rocker panels worn where the doors come in contanct with panel. Link kit and bushings of front suspension worn and made klunking noise going over bumps at low speed. 
182000 mi

US $165
Loud Whining noise coming from the front. Replaced left front wheel hub assembly, did the left side 3 yrs ago. 
25700 mi

US $1000
Clutch went at about 26,000 miles. Was always easy on the clutch too. First car I ever had, I needed to replace the clutch. ALSO...Need to go to dealer for recall. Power steering fails at times, ignition turns off at times. Recalls 
30300 mi

US $800
Front end, suspension, axle. Low miles too. 

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2007 Saturn ION 4dr Sedan

266-horsepower 3.5L V6 4-speed automatic FWD

26000 mi

US $200
Loud suspension rattle due to defective control-arm-bushing on front-driver-side. Owner paid mechanic to replace defective control-arm-bushing on front-driver-side. 

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2007 Saturn ION 4dr Sedan

175-horsepower 2.4L I4 5-speed manual FWD

37820 mi While making visual inspection, mechanic noticed that the rear shocks needed replacing. Dealer replaced them under warranty. 
46500 mi

C $400
Front shocks leaking. Replaced. Had to fidget key in contact to start the car. Ignition switch replaced. 
67580 mi

C $500
Problem with the suspension causing noise when going at low speed. 

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2007 Saturn ION 4dr Coupe

355-horsepower 5.4L V8 4-speed automatic FWD

67000 mi

US $100
Door seal super slow leak. 
114000 mi

US $820
Heater core strangely started leaking one day. Very unusual to happen on these cars, which is why the part cost so much (no one carries it in stock, even dealer)! Had it fixed in 1 day; however, it is a 5 hr labor rate. 
157300 mi

US $740
Replaced front struts and rear shocks. 
182000 mi

US $1200
Camshaft Position Solenoids and Timing Chain Replacement 
193000 mi Emissions Purge Valve replaced. 
196000 mi

US $880
Passenger-side Inner Tie-Rod replacement. Replaced both Control Arms due to Subframe rubber bushing wear. Also included new ball joints as they are part of the Control Arm assembly. Rear fuel line replacement, both High and Low Pressure lines. Fuel Filter included. 
197000 mi

US $700
Steering Rack replacement 

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2007 Saturn ION 4dr Coupe

306-horsepower 3.5L V6 5-speed manual FWD

11160 mi Cruise control works only sometimes. Driver's door exterior trim came loose. Ignition keys broken where the key ring attaches. 
22940 mi PCV hose cracked and dripping engine oil. I described the exact location but they still said "no fault found". Cruise control sometimes stops working after driving for more than 20 minutes. They said there were no codes and therefore nothing more they could do. They didn't even drive the vehicle. Received a letter from GM instructing me to get my electric power steering motor replaced if I had experienced any "PRW STR" warning messages. Dealer said there were no recalls and would not investigate further.  Exhaust rattles after engine is started and sometimes while driving. Dealer said they could not duplicate the concern. Engine knocks/rattles very intermittently at idle once at operating temp. Dealer would not investigate further since I could not reproduce the noise when I dropped off the car. 

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2007 Saturn ION 4dr Coupe

266-horsepower 3.5L V6 5-speed manual FWD

94000 mi

US $294
Replaced rear shock absorbers 
97300 mi

US $28
Replaced worn manual shift boot, repainted shift lever 
104000 mi Replaced fuel tank heat shield retaining screw(s). 
109000 mi

US $232
Electronic Control Module (ECM) had to be reprogrammed due to throttle body cleaning. 
126300 mi

US $120
Replaced left and right headlight assemblies (lenses). The OEM lenses were foggy. 
127000 mi

US $1469
- Could not change gears (manual transmission) - Diagnosed as bad clutch hydraulic slave cylinder - New clutch kit / slave cylinder installed to correct the problem. 
66700 mi Electric Power Steering failed, burned out motor, repaired under special warranty/TSB. 
100000 mi

US $800
Replaced struts, rear shocks,sway bar bushings Replaced condenser, purge and recharge refrigerant 
114000 mi

US $1200
Replaced front wheel bearings Replaced corroded fuel line 

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2007 Saturn ION 4dr Coupe

266-horsepower 3.5L V6 4-speed automatic FWD

35000 mi it had leaking front struts on the front 
37000 mi Brakes were making noice when driving car for a long time. 
44000 mi the power steering would go out, fixed 
63000 mi

US $1150
Blew out engine. Replaced engine. 
60720 mi

C $700
Front right hub assembly needed to be changed but I changed both of them (left, right). Also changed rotors, pads, drums and shoes as maintence - this was the first time the brakes had been done. 
64760 mi

C $175
Needed to change the tumbler (key started to get stuck at times) and have original key coded. 
76880 mi

C $260
Right front Hub/bearing started to make noise. Replaced both front Hubs. 
84900 mi

C $250
- Both lower control arm bushings worn - had both replaced. - One worn stabilizer link replaced. 
91120 mi

C $120
Fuel line from tank leaking due to corrosion. Replaced a portion of the fuel line. 
36320 mi For 3rd time in 56,000 kms the front end bushing were replaced due to being totally worn out. Took car into the Chev dealer due to an ice packed sound in the rear end during - 0 temp driving. Noise is very loud. Rear ones are still worn out. 
37820 mi

C $299
Rear 2 bushings holding the rear axle to the body. 
38620 mi

C $299
Muffler shop Apr 21 determined that the snap on the front driver side was a swaybar link problem. Both rear shocks leaking. 
39520 mi

C $300
both rear shocks were leaking a lot Dealer missed both while working about 3 inches away from peoblem charging me for their failed repair of parts.  
40300 mi

C $150
clunk in front end repeated on small road imperfections. Dealer could not find problem. Driver side Sway-bar link assembly needed replacing. Muffler shop noticed during oil change. 
40920 mi

C $41
Clunk when shifting from Park to Reverse and slight noise from Reverse to Neutral. LARGE BANG when shifting from Neutral to DRIVE. Tech heard it for almost 10 minutes but next day could not replicate. T old not 2 worry about it 
47740 mi Wheel bearing passenger side had been replaced 2 yrs into ownership 2009. Vibration as if driving on rumble strip. Bearing worn out. Driver side checked at same time of repair and replaced as well 
52700 mi

C $80
warranty on CV boot driver side. Did alignmment at same time 
65100 mi

C $300
Replaced sway bar link as well as rear spring coils 
71260 mi

C $410
HAD TO REPLACE PASSANGER SIDE FRONT WHEEL BEARING FOR THE THIRD TIME. 
79140 mi

C $325
Replaced 4th control arm bushing. Replaced rear Monroe sensatrac shocks under warranty parts only. 
89900 mi recall on ignition switch and ignition oddly this car has been owned by myself since showroom and had the same shut off several times reported to Saturn dealer before their demise and this recall. glad my family was never injured. battery died following ignition key not being able to be shut off. This was the 5th time this occured only this time the battery froze. one month later GM issues recall notice on the identical issue. dealer says its not a recall but TSB 

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2007 Saturn ION 4dr Coupe

175-horsepower 2.4L I4 5-speed manual FWD

6200 mi The mechanics saw the problem was imminent during a previous maintenance visit. During this maintenance visit, both control arm bushings were replaced, because they split. This is a common issue on this model. 
12400 mi Both control arm end links replaced. Again. Common issue. 
14900 mi RPMs were not dropping while coasting with the engine not in gear. RPMs remained at ~1500 until full stop. Issue appears to be fixed for now after a computer reflash. 
37800 mi

C $480
fuel pump leaking gazoline smell 
48980 mi replaced front wheel bearing 
55180 mi

C $1300
Had to replace the compressor 
57900 mi

C $560
replaced injectors 
61680 mi

C $430
gazoline leak from the line 
62000 mi

C $200
replace both coil springs and rear shocks 
63840 mi

C $1000
Replace both control arms, front shocks, and stabeliser link kits 
64480 mi

C $80
Replaced exhaust solenoid 

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2006 Saturn ION

Engine not specified

39680 mi dipstick was popping out. Turned out to be a pinched pcv line on the back of the engine 
50840 mi loose stabalizer arm knuckle 
87000 mi

US $560
rear wheel bearing bad had to replace entire hub asesembly--other side will need to be replaced soon  
84500 mi

US $650
Car began leaking heavily around all doors and windows 
110000 mi

US $100
Wheel bearing is getting terribly loud. I had to fix it. With the low value of the ion, I'm just sticking to one wheel bearing and not replacing the other. 

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2006 Saturn ION 4dr Sedan

355-horsepower 5.4L V8 4-speed automatic FWD

103000 mi

US $483
Intermediate Steering Shaft removed and new part installed. stabilizer link bushings removed - new parts installed. 
55180 mi

C $574
Hear rattling noise in/near steering column. Similar to when i had steering column replaced a couple of years ago. Tech didn't detect the noise, he inspected steering components and didn't see anything. Still hear it, not too serious yet. 
78580 mi

C $1760
New brakes all around (new pads, rotors, drums and shoes) New control arm bushings (both) New sway bar (right front) coolant flush, new brake fluid, fuel line recall check, 
79360 mi Check engine light was on. Flashed ecm with new firmware. Made car worse. Will be bringing it in again soon. 
89280 mi

C $1100
Replaced both front struts that were serverely needing replacement 
102300 mi

C $230
Bushings Flex pipe rusted through 

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2006 Saturn ION 4dr Sedan

201-horsepower 3.5L V6 4-speed automatic FWD

17000 mi

US $45
seat cover latches keep popping off , resulting in seat cover coming off seat, seems to be unresolvable intermittently, check engine will come on as well as abs, brake, no codes are stored, so nothing gets done about it 
21000 mi Struts went bad. 
33000 mi

US $100
drivers window not working; found window regulator no good (again) *found window regulator no good (again) When fueling, pump keeps stopping. Bad tank purge solenoid. *bad tank purge solenoid. 
34000 mi

US $100
continual problem with drivers window, got stuck and had to replace regulator 3 times then finally clips that hold glass in place on regulator, will see if this works, 4th time being repaired. 
34500 mi

US $100
check engine light, gas tank needed to be replaced has a built in valve that is defective, wheel hub bearings also no good, making loud noise. 
20000 mi replace passenger side conrtol arm bushing 
21000 mi Replaced driver side control arm. 
27000 mi replace control arm bushing 
42300 mi

US $145
Lower control arm bushing replacement 
58000 mi

US $800
Failure of the ECM logic cxircuits. 
131000 mi

US $150
Power steering failed while driving. Upon restarting the car, the power steering restored. Mechanic evaluated problem and replaced a blown fuse. 
135000 mi

US $1500
Power steering fails, then reboots when the car is restarted. This is a constant problem. With the repair estimated at over $1500 on a car worth under $3k, we will be buying a replacement car instead of repairing. Common issue on 2006 Ion2 
139000 mi Head gasket blown and the car is now junked. Steering also never fixed. 
52000 mi correction of a power steering issue that was done under recall. experienced power steering failure several times previously. 
59000 mi replaced rear shocks 
76500 mi

US $230
Ignition column needed to be replaced as the key was stuck in the ignition. 
94300 mi

US $900
Replaced front shocks and struts 
29000 mi Car would not start a few times. Dealer found no error codes, so dealer did nothing. As an aside, dealer updated engine software. 
31000 mi Car would not start again. Dealer found error codes. Dealer replaced ignition switch at no charge, since car is still under warranty, and this is a known issue. As an aside, dealer performed 30,000-mile maintenance. 
55000 mi

US $500
Check engine light came on. Diagnosis result: engine thermostat was 'barely functional'. Actions taken: Replaced thermostat and flushed radiator. Problem fixed. 
59000 mi

US $400
Turn signal bulb burned out. Third time in one year. Previously burnt out bulbs left melted contacts. Shop cleaned up contact area and replaced bulb. 
59000 mi

US $400
Both shock absorbers leaking fluid. Replaced both. Riding experience improved noticeably after repair. 
79000 mi

US $300
Transmission coolant line leak. Part had to ordered from Detroit since even local GM/Saturn dealer did not carry it. Paid $40 extra for next-day shipping. Problem solved. 
79000 mi

US $300
Key stuck. Had to replace gear shifter assembly, ignition cylinder, and ignition housing. Then the steering wheel became stuck and the airbag light went on. Replaced clock spring, too, and now everything runs fine. Lower front control bushings worn out. Had to order part from Detroit. Turns out, the rear bushings need to be repaired, too, but I'm waiting for another time. Rear passengers will still feel bumps when riding. 
85000 mi

US $400
Very bumpy ride. Rear passengers get carsick. Bushings/front strut links replaced. Ride quality significantly improved after repair. 
93000 mi

US $500
Problem: Engine light flashing and rough acceleration. Error code diagnosed as misfire in cylinder. Coil pack replaced. Repair completed successfully. 
104000 mi

US $250
Trunk support bar snapped in half. Trunk unable to stay open. Replacement part required special order. Once repaired, the trunk is good as new. Paint stripped off the rocker/runner area where people step on before entering car. Shop repainted entire area and touched up other scratches elsewhere. Shop matched paint so car still looks good after 100,000 miles. 
105000 mi

US $180
Front struts were worn and had to be replaced. Re-lubricated all bushings and related chassis parts. Ride is smoother but you can still hear creaking sound at low speeds. 
109000 mi

US $1180
Airbag error light appeared on dashboard. Mechanic determined that air bag sensor in the front passenger seat was faulty. Had to replace the entire housing unit in the seat and get a GM technician to reset the error light. 

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2006 Saturn ION 4dr Sedan

170-horsepower 2.4L I4 5-speed manual FWD

55000 mi Power steering became unoperable for a short trip was advised to take into dealer for safety 
35000 mi Steering wheel made a rattle when turned 180 degrees or more. Bad cruise control switch found - part ordered. 
35000 mi Steering wheel made a rattle when turned 180 degrees or more. Bad cruise control switch found. Wrong part was ordered on 2nd visit, had to return for 3rd visit to get correct ordered and installed. 
56000 mi RF wheel bearing assembly made droning noise at 25 mph and above. 
57000 mi Replaced intake camshaft position sensor. Replaced exhaust camshaft position sensor. Worn CPS units caused revs to stay up between shifts. 
62000 mi L and R front sway bar links loosened. Dealer replaced clamps, insulators, bushings and link assemblies. Worn intermediate steering shaft replaced, car's front end clunked and popped during turns at low speeds. 
70000 mi

US $88
I smelled gasoline while outside the car. Called retailer. Verified there is a TSB on replacing fuel pump module. Local Chevrolet dealer did the work as Saturn no longer exists. RR belt molding was replaced after original shrank and left gap which could have allowed water intrustion. Passenger side visor broke, would not retract against roof. 
75000 mi Catalytic converter broke internally at ~73,500 miles, replaced and covered under 8/80,000 mile emissions system warranty. 
78000 mi Driver's side sun visor refused to stay "up" or rest against roof, often dropping into my light of sight and brushing against my head in certain situations. RF belt molding shrank to due long-term weather exposure; it was replaced while car was in shop for non-related body work. 
80000 mi

US $530
Front lower control arm bushings and front sway bar end links/bushings were failing. They were replaced. 
92000 mi

US $440
Replaced shock absorbers and struts. They were 6.5 years old and the mechanic implied at least one was leaking. I decided to heed the recommendation before it became worse and one or more units failed. Shop said end links bad. Compared prices, found dealer cheaper, went there. They said end links fine, but other parts not. L outer tie rod needed replacing. L outer CV boot torn and leaking, replaced. 
102000 mi

US $587
Car leaked coolant; water pump leaked at weep hole. Replaced water pump. 
102000 mi

US $387
Front crankcase seal leaked and needed replacement. Power steering assist motor began to fail. Replaced under extended warranty from manufacturer. 
111000 mi

US $377
Droning noise from front heard at 25mph and above. Dealer replaced LF wheel bearing. 
120000 mi

US $803
Fuel lines corroded, leaked due to age/rust, causing starter to crank longer than usual. Car became harder to start when cold. 
120500 mi

US $414
Muffler had hole and began to crumble internally. 
121000 mi

US $966
Only RF power window and locks worked. Other windows and power mirrors failed. After replacing door switch, BCM, it took new BCM and wiring repairs to solve the problem. 
124000 mi Traction control failed; may just need a new fuse. 

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2006 Saturn ION 4dr Coupe

355-horsepower 5.4L V8 4-speed automatic FWD

18600 mi sway bar bushing 
24180 mi ABS light on and abs action when braking. Left front wheel bearing replaced. 
26040 mi Front wheel bearing replaced. 
21000 mi Car shuts off unexpectantly making right hand turns at slow speeds. 
25000 mi replaced transmission ignition interlock module - key would not disengage from steering column 
29000 mi Fuel pump in tank had to be replaced leaking fuel externally 
30000 mi

US $70
Exterior door trim fell off car while driving down the freeway 
46000 mi Electric Servo Steering motor quit working causing steering issues. TSB. 
54000 mi

US $50
When turning or going over speed bumps, there would be loud noises cluncking. 
34000 mi Power Steering warning came on and the power steering failed a few minutes later, Car had 1 day left on warranty so no charge for tow or fix 
56000 mi

US $431
Ignition frozen with key stuck, could not turn car off. 
59000 mi

US $265
The driver's door flew open making a right hand turn. Door would not close. Door latch replaced. 
64000 mi

US $80
Dealer serviced coolant which had air pockets causing occasional coolant low warning. Replaced battery 
66000 mi

US $138
Sunroof drain clogged, causing interior water leak. 
81000 mi

US $210
O2 sensor 1 
82000 mi

US $24
Replaced headlights 
58280 mi

C $70
Swaybar End-link 
74400 mi

C $359
Wheel Bearings... Driver front wheel bearing failed, causing loud noise and some vibration. Passenger side was replaced at same time for peace of mind. appro $159 per bearing. 
156860 mi

C $450
Exhaust camshaft actuator causing transmission to turn to left front axle seal and transmission service 
11780 mi In a week which averaged -40 celsius weather the security system need to be rebooted and the ignition switch replaced. Apparently it was a common problem that week for that make of car according to the dealership. 
13020 mi The cruise control went, apparently a problem on the vehicles was fixed in 2 hours. 
17360 mi Power steering went out. 
18600 mi Engine light came on. Took it too shop. Apparently I had a fuel line partly freeze up during very cold -30 Celcius weather. That caused engine light to come on had thawed by the time I got it to the shop.  
31000 mi

C $700
Severely cracked window, replaced. Cause unclear. Arrived at a friends after four hour drive, didn't have crack, went out that night and I did. It wasn't a chip but a crack that quickly spider webbed through the glass. 
32240 mi

C $55
Would not turn over happened in January. Replaced battery. Happened again, but this time battery fine. Could not replicate problem. Has not happened since that time. 
33880 mi

C $150
Engine warning light was on it, appears that it was a false warning caused by a sensor problem. 
40520 mi

C $300
Had to replace carburateur 
55800 mi Saturn ion ignition recall my key got stuck in the ignition so I got a loaner until the parts came in 
68600 mi

C $700
Saturn Ions have a GM recall on the power steering. It goes out while driving 
73620 mi

C $2500
Timing chain needed to be replaced 
22940 mi Weatherstripping on the rear door ripped. Check engine light was on for a few days, however by the time I was able to bring my vehicle in, the light had already been off for a week and the computer showed no history. Noticed a wobbling noise under heavy breaking. Basic brake maintenance performed to clean out dirt and rust. Replaced rear door weatherstripping. 
23560 mi Injectors out of balance, installed 4 new updated injectors and performed reprogramming. 
26040 mi Both front control arm bushings torn out. 
30380 mi Left front sway link worn. 
34100 mi

C $440
replaced both front sway bar links 

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2006 Saturn ION 4dr Coupe

201-horsepower 3.5L V6 5-speed manual FWD

24180 mi Changed both lower control arm bushings. Changed HVAC Blower as it was noisy. 
25420 mi Ignition switch causing no start issue. Replaced ignition. 

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2006 Saturn ION 4dr Coupe

201-horsepower 3.5L V6 4-speed automatic FWD

35000 mi Rattle from driver's side door frame. Shop added a spacer under exterior trim, removing rattle. Shop checked door internals and seals to be sure trim was the source, and tested after repair.Noise is gone, repaired under warranty without hassle. 
63000 mi

US $1200
suspension work was somewhat preventative, front sway bushings were sheared and required replacement. hard to assign $ to "reactive" vs "preventative" work, a lot of the labor overlapped 
76000 mi

US $800
Replaced stabilizer links and front R wheel bearing (unplanned) O2 sensor had been causing a CEL, replaced. (planned) Confirmed suspected exhaust/muffler leaks, putting that maintenance off until spring. 
78000 mi

US $120
Repaired exhaust leak, simple exhaust piping replacement using generic tubing and old heat shields 
91140 mi

C $100
Car only needed a new battery. 
92380 mi

C $200
The bolt holding passenger rear shock came loose and fell off. Replaced both rear shocks with new ones. 
93620 mi

C $340
Loud noise/grinding due to failing front right Hub. It was replaced with a quality part. 
102540 mi Car in for new Ignition Switch based on recent Recall. 
108500 mi The spark plugs need to be replaced in the ION but all 4 are seized in the head (original plugs). This car is still drivable but not as fuel efficient as it could be. 
121520 mi Crack windshield - replaced and drivers side window dislodged from the track and needed to be re-installed/tracks lubricated. 
127720 mi Steering linkage stiff - replaced 
139500 mi Exhaust hangers broke due to rust and flange bolts. New hangers welded and flange bolts added to exhaust which is still in good shape and the original system. 
60000 mi

US $400
Control arm bushings replaced. Power steering failure. 
61000 mi Ignition switch and key cylinder replaced as per recall. The key cylinder would occasionally not fully rotate back to the off position, leaving the key stuck in the cylinder and necessitating the use of the manual release button under the steering column. 
65500 mi

US $1000
Both front struts and rear shocks replaced due to significant leaking. Significant fuel leak developed at the fuel pump assembly. Unit replaced. 
83000 mi

US $500
Radiator fan failed and required replacement. 
24000 mi

US $133
Freon was recharged. 
25300 mi Fuel pump module leaking. Replaced free of charge by dealer as part of special recall by General Motors. 
25700 mi

US $528
Front struts were replaced. 
26000 mi

US $280
Check engine light came on. Air pump had failed and was replaced. Check valve had to be replaced 
30000 mi

US $375
Wheel hub assembly was replaced. 
88000 mi

US $32
Driver door plastic "pillar" applique broke at screw mount; replaced applique.  
112000 mi

US $30
Passenger front door trim "belt w/strip" replaced due to heat distortion. 
113000 mi Electric power assisted steering intermittant. Known problem addressed by TSB. 

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2006 Saturn ION 4dr Coupe

170-horsepower 2.4L I4 5-speed manual FWD

80600 mi

C $300
Shocks were going when I purchased the car at 77 000kms. At about 112,000kms, not longer could safely drive car. Back shocks replaced and fronts need to be done. *dupe Shock failure. Back shocks replaced and fronts need to be done 
84940 mi This was the electric steering problem which finally became untenable. Recall. 
94240 mi

C $550
Shocks were replaced 
107220 mi

C $350
all shocks and front bushings 
119640 mi

C $100
Purchased wheel bearing and installed myself Replaced struts, NOT quick struts Left and right control arms Replaced hub/bearing Replaced rotors and pads 
120900 mi lock down mechanism on sun roof broke on both sides and unrepairable and replacing sunroof is the only way to fix it and not an option. extremely expensive. stupid that GM will not supply individual parts for sunroof and it is a part that wy 
128340 mi Recall for ignition switch and cylinder. But before they called me in to change it over, the ignition cylinder locked up with the car running and I could not turn it off(had to remove the ignition relay to turn the car off and disconnect the battery). 
130840 mi

C $50
Variable valve timing sensor on intake side failed. Replaced. 
138880 mi

C $40
Ignition coil cylinder one failed 
154540 mi

C $35
Thermostat failed. 
159980 mi

C $40
*d thermostat failed. Replaced thermostat. 
167400 mi

C $46
Failed side mirror adjustment switch. 
171740 mi

C $56
replaced cruise set/resume switch. Left front window side molding replaced 

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2006 Saturn ION 2-door

4-cylinder manual 2WD

49000 mi

US $130
Sway bar bushings and endlink bushing were worn and caused clunking while driving over bumps and back-and-forth steering 

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2005 Saturn ION 4dr Sedan

200-horsepower 3.5L V6 5-speed manual FWD

66500 mi

US $128
Replaced shocks and spring seats 
68700 mi

US $78
Radiator fan needed to be replaced. 
73000 mi

US $100
Replaced Front Oxygen Sensor and coolant sensor 
159000 mi

US $300
noise from front suspension, replaced bushings and control arms and stabilizer links 
168000 mi

US $20
Replaced thermostat 
73000 mi

US $93
Control Arm Bushing came loose from its mounting. Replaced control arm 
104000 mi

US $75
Stabilizer bar links and bushings replaced due to rattling 

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2005 Saturn ION 4dr Sedan

200-horsepower 3.5L V6 4-speed automatic FWD

59000 mi Took car in for yearly PA. state inspection. Car would not pass state emissions test due to bad gas cap. Dealer service replaced gas cap. 
64500 mi

US $70
Replaced clips that held driver side window to power window track ..took to local glass shop 
65000 mi

US $200
Both rear shocks replaced after I noticed one was leaking..car does not bounce so much going over rough roads 
72000 mi

US $400
replaced rear drum brake cylinders 
75000 mi

US $8
Car was running a tiny bit hot according to temp gauge. Checked to find upper radiator hose was collapsing due to negative pressure in cooling system. Replaced screw on cap on overflow reservoir. Problem solved. 
79000 mi

US $262
Replaced both front stabilizer link bars as the y were worn and loose. front end noise going over bumps stopped had both rear shocks replaced as rear end bounced a lot 
81000 mi

US $326
front right wheel bearing was replaced as it was noisy 
93000 mi

US $150
Both rear shocks replaced for Pennsylvania state inspection due to leaks. 
99000 mi

US $65
Replaced both front end Mcpherson struts and coils Replaced the coolant recovery tank and hose engine supply hose from the tank to the engine. Old one was leaking from the bottom near the sensor. New one came with sensor and cap. 
107000 mi

US $174
One of the trunk lid torsion bars that hold up the deck lid when opened snapped on its own. I had to replace both the torsion bars as they work as a set. trunk/deck lid now is able to stay in the open position.... 
49000 mi

US $236
I paid for the ignition switch replacement though it was replaced not 20,000 miles ago under warranty. The BTSI sensor [$400.00] was covered by GM as it had been replaced 20,000 miles before as well. Update: GM later refunded the rest. 
61300 mi Recall ignition switch and cylinder. The 2011 repair lasted a little over a year and 3000 miles. I've been diddling a little tab under the steering wheel to get the key to release. 
65000 mi

US $381
Bushing on sway bar went out again after less than 30,000 miles. 1st time was under warranty. Recall for ignition key only partially successful. Key would still not come out after repair. TSB was issued by GM for this condition. Shifter replaced because of open circuit 
92500 mi

US $580
Struts 
75500 mi

US $45
Bad oxygen sensor "upstream", means before catalytic converter. Replaced sensor. Had to replace both stabilizer links, and sway bar bushings. 
78000 mi engine coolant light comes on. Needs new coolant surge tank. 
90000 mi

US $890
replaced shocks and struts 
91000 mi

US $475
ignition switch lock cylinder replaced during GM recall failed (key will not turn). Found dealer recall 'repair' damaged switch housing to where lock cylinder replacement ineffective, need to replace the entire switch and housing 
70000 mi

US $100
Replaced lower control arm bushings, stabilizer end links and bushings by myself 
112840 mi

C $500
One front bearing changed. 
161200 mi

C $600
Serviced Catalytic Converter 
85000 mi

US $90
Blinkers inoperative. Replaced wiring harness. 
94000 mi

US $600
Swaybar links replaced on both sides. 
115000 mi

US $85
Broken windshield wiper transmission. 
146700 mi

US $150
Excessive noise at front driver side wheel. 
160000 mi

US $250
Fuel line leak near rear driver-side tire. Found excessive corrosion on the line. Replaced with new lines. 
59000 mi

US $150
p0455 error, can't solve it, put new gas caps still happens. can't find parts that need attention on the car, don't know where to look 
70000 mi

US $291
emissions problems suspension problem 
70000 mi

US $106
transmission lines leaking 
82000 mi had problems with the inside door switch. also with the security system locking my start up. thanks for google and all the help there. 
93000 mi

US $10
cruise control, replaced the up-down switch. it works now. 
54560 mi

C $35
Does not start, Passlock lignt and other lights flashing. 
57660 mi

C $115
Replace Right front Sway bar link 
58680 mi

C $50
HVAC Blower fan stop working in low and medium speed. High speed is working. rnReplaced HVAC Blower motor Resistor. 
60440 mi

C $125
Replace front Left Wheel Bearing. Replace rear brake cylinder(Right and left). 

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2005 Saturn ION 4dr Coupe

306-horsepower 3.5L V6 5-speed manual FWD

63000 mi

US $100
Slow coolant leak. Dealer replaced water pump. 
75000 mi Cat convertor flex pipe cracked. Replaced under Federal Emmissions requirement 
80000 mi

US $550
Replaced struts shocks 
115000 mi

US $300
Crankshaft position sensor failure 
118000 mi

US $680
Check engine light was still on after I replaced the crankshaft position sensor myself. Code said I needed to do a CASE relearn.  The dealer also found another code indicating the coolant temp was too low. Also replace a failing thermostat. 

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2005 Saturn ION 4dr Coupe

200-horsepower 3.5L V6 4-speed automatic FWD

85000 mi Shocks, Struts, Break Pads and Rotors. 
36000 mi

US $1100
Clunking noise from front suspension. Shop diagnosed as needing a new steering yoke. Battery would not hold a charge. Replaced battery. 

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2004 Saturn ION

Engine not specified

70000 mi

US $496
to pass state inspection - front linkage replacement & rear shocks; regular maintenance oil/lube, winterization - fluids & windshield wipers; recent previous repair - transmission serviced for gear slipping & new front tires 
70000 mi longterm, chronic intermittent starter failure, 2009 spring ($360) and Jan 2010 replacement of starter (warranty); diag-starter burned; optional bypass ignition system installed; electrical failure system; unresolved; not happy 

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2004 Saturn ION 4dr Sedan

264-horsepower 3.2L H6 5-speed manual FWD

157000 mi Rear shocks replaced Replaced A/C connector that melted. Replaced sunroof switch, trunk remote switch. Replaced ignition switch. Replaced driver's side mirror and windshield mounted rear view mirror. 
63000 mi

US $380
Humming noise at speed, wheel bearing bad. 
226000 mi

US $223
Batt warning light. Tested battery, ok. Bench tested alternator, failed test. Replaced alternator and serpentine belt. 
228000 mi

US $400
Heard growling from right front that increased witn speed. Removed wheel, spun bearing by hand. Grittiness and noise confirmed failure. Replaced both sides. 
245000 mi

US $117
Starter failed. Checked all fuses, relays, neutral safety switch. Replaced starter. 
85000 mi sway bar links-replaced with moog greasable units 
86000 mi

US $482
ignition switch would not go to start position. replaced lock cyc and housing it goes into. also could not get steering wheel off so they had to get a new one. 
107000 mi

US $280
wiper transmission needed replaced 
53000 mi

US $340
Ignition control module and coil pack shorted, causing car to misfire under a load. Replaced driver and passenger side wheel bearing/hub assy. 
221000 mi

US $278
*duplicate Wiper mechanism malfunction. 
223000 mi

US $160
Mechanism of left windshield wiper was replaced 
242000 mi

US $360
Sway bar links had to be replaced replaced alternator clutch pedal replaced *error A bushing that is part of the driveshaft was worn and had to be replaced. The cost for the repair also included draining and replacing the transaxle lubricant and came to about $360. 

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2004 Saturn ION 4dr Sedan

264-horsepower 3.2L H6 4-speed automatic FWD

72000 mi

US $365
Piece of housing around radiator fan broke off and caused damage to fan. Cause of severe rattling and noise. If left as is the damage would have worsen and lead to major radiator damage.  
107000 mi

US $2100
Had 4 shocks replaced 4 struts replaced and 4 bushings replaced.  Also had the headlights cleaned/buffed. 
112000 mi

US $80
Check engine light. Repair shop forgot to put oil cap back on. 
133000 mi Sway bar link, control arms and steering end links 

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2004 Saturn ION 4dr Coupe

306-horsepower 3.5L V6 5-speed manual FWD

76000 mi Saturn had sent me a notice of possible issues with the catalytic converter on my Redline. I had had some of the symptoms that they mentioned. ie SES light comes on for no reason in cold weather. Sometimes a loss of power in cold weather. 
95000 mi

US $100
I had a clunking noise coming from the front end of the car. I replaced the swaybar bushings and endlinks. The endlinks were probably fine I figured I'll have them off might as well replace them also. Car runs much better now. On really cold days the car would not start. From visiting saturnfans.com I found the problem was the ignition switch setting off the security mode. Bought replacement switch and installed easily. No problems since. 
119000 mi

US $430
The crankshaft positional sensor started to go bad. It would sometimes cause the car to take multiple attempts to start. It never did leave me stranded though. 
128000 mi Coolant sensor went bad. Replaced the coolant reservoir and that fixed the issue. 

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2004 Saturn ION 4dr Coupe

302-horsepower 4.6L V8 5-speed manual FWD

57000 mi

US $600
front bushings and 60,000 check 
58000 mi

US $540
Air conditioner quit blowing cold air when car stopped or idle. Replaced radiator fan. 
60000 mi

US $250
New shock absorbers for rear of car. 
61000 mi

US $700
Got new struts and shocks for front of the car. 
83000 mi

US $213
Car made shuddering, stuttering noise in the area of left front tire when braking or getting up above 60mph. The shop corrected the problem (somewhat) by tightening [something]. Complete correction would cost 1000+; they advised waiting. 
95300 mi

US $800
Leak from cracked engine block. 
103000 mi

US $750
Engine Block Cracked 
134000 mi Glitchy transmission, couldn't acceleration above 35 mph, start-and-stop behavior 

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2004 Saturn ION 4dr Coupe

264-horsepower 3.2L H6 4-speed automatic FWD

34000 mi

US $75
Replaced Swing Arm Bushing. 
41000 mi Sway bar bushings went bad 

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2003 Saturn ION

Engine not specified

64000 mi

US $150
Front Sway Bar Links 

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2003 Saturn ION 4dr Sedan

264-horsepower 3.2L H6 5-speed manual FWD

110000 mi Passlock problem, dealer offered free repair upon $50 deductible = rejected.  Other repair the same day original FW bearings replaced !!760$(tax incl). 
109000 mi

US $490
Lower control arm bushings worn - car had made clunking, squeaking noises for some time. 
121700 mi

US $600
Replaced struts and shocks after 9 1/2 years. No complaints 
107000 mi Suspension Noise most likely sway bar bushing and end links. 
142000 mi

US $70
Changed drivers side CV Joint due to bad popping. Problem is solved. Also replaced control arm bushings. 
150700 mi

US $500
Manual transmission internal transmission burned up due to slight transmission leak. Driver side wheel bearing was replaced because noise/vibration/and too much free-play. 
157300 mi

US $300
Replaced clunking Drivers side CV axle. Replaced Wheel bearing due to noise. 
166000 mi

US $350
Replaced tie rod ends, ball joints, sway bar bushings, end-links. Replaced clogged fuel injector and seals. 
68200 mi

C $450
Stabilizer link replaced. 
33940 mi

C $470
The flex pipe was leaking that had been replaced two years ago. The cat converter along with flex pipe from Walker was changed. I supplied this part and gaskets, labor was $120 and parts $350. 
52080 mi

C $350
Front wheel bearings noisy 
53100 mi

C $150
the rattle in the exhaust system was resolved by removing part of the heat shield. 
53940 mi

C $200
Loud noise in front end on bumps. Rear end bounce on bumps 
55800 mi

C $70
Starter replaced due to disengaguement problem 

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2003 Saturn ION 4dr Sedan

264-horsepower 3.2L H6 4-speed automatic FWD

350000 mi

US $700
every 100K new tie rods, control arms, bushings... 4 set. 
136000 mi

US $70
alternator replaced. belt replaced. suspension clunking on bumps. swaybar bushings and end links replaced with Moog parts. 
136000 mi

US $90
ball joint rubber boot torn. replaced both control arms. 
136000 mi

US $45
intermittent no start. only solenoid click. starter removed and rebuilt. probably bad solenoid. 
136000 mi key stuck in ignition due to faulty transmission switch. covered by extended warranty. 
136700 mi check engine light for O2 sensor. code deleted, didn't reappear. 
137000 mi check engine light for vacuum leak. code deleted, didn't reappear. 
140000 mi

US $50
Noise on start. Timing chain tensioner replaced. Noise still there. 
142300 mi Water in trunk. Rubber plug missing on left side. Air vent sealed with sealant. CV boot leaking. Sealed with tape and zip ties. 
143000 mi

US $30
O2 sensor light. Sensor replaced. 
92000 mi

US $1000
Struts needed to be replaced. Replaced radiator hoses. 
94000 mi

US $750
Transmission was building up pressure and forcing the car to "bang loudly" when downshifting... Dealer replaced fluid and reflashed transmission. After a week problem still occured. Dealer suggested replacing valve body or rebuilding the trans.  
89000 mi

US $190
Passlock would randomly fail, refusing to recognize my key & preventing the car from starting in 15 minute blocks, sometimes several times in a row. Ignition switch was replaced at my request based on my own research into this issue. 
92000 mi

US $798
Wheel bearings went bad. The front hub assemblies had to be replaced. 
58000 mi

US $300
Door panel was loose at the bottom of the door frame 
64000 mi

US $580
REPLACED FRONT WHEEL BEARINGS 
113000 mi

US $326
Car would not start. I replaced the battery and the car still wouldn't start.I had to replace the starter. *dup Car would not start. I replaced the battery and the car still wouldn't start.I had to replace the starter. 
135000 mi

US $282
Replace right front wheel bearing assembly. 
156000 mi

US $270
Replace gas line and filter,repair exhaust leak. 
164000 mi

US $93
Replaced middle exhaust pipe as it was leaking. 
166000 mi

US $773
Had to replace shocks and struts. 
181000 mi

US $539
Replace Tie Rod on left side. 
183700 mi

US $187
Replace sway bar. 

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2003 Saturn ION 4dr Coupe

302-horsepower 4.6L V8 5-speed manual FWD

107000 mi

US $374
I replaced the front struts and rear shocks due to the banging on the floor board caused by the traction bar. 
118000 mi Very high rpm at times, put it in neutral and sometimes shut it off to stabilize. Check engine light a couple of times, code pointed to the throttle advance sensor. Twice bought sensor and found it didn't fit engine. Not fixed when totaled. 
71000 mi

US $890
Loud growling noise. Replaced both front wheel hub bearings. 
72000 mi

US $2300
replaced CVT due to P0700 DTC 
73000 mi

US $3000
Found antifreeze leaked into cylinder #4 spark plug cavity. Cylinder head cracked. Replaced with a rebuilt unit.  
73000 mi

US $55
replaced both rear shocks due to worn out original units. 
83000 mi

US $225
found crack in fuel line between fuel filter and engine. mechanic replaced the rusted sections with a comparable brake line tubing. 
88000 mi

US $70
Heard some clunking noise from front end. Replaced both side Stabilizer End Links. 
89000 mi

US $110
Loud clunking noise from front end when it ran over potholes. Replaced front stabilizer bar bushings. 
99000 mi

US $250
The familiar front wheel hub bearing noise occurred. The previous pair that Firestone had installed only lasted two years. This time, I refused to pay Firestone another ripoff $875 and replaced them myself. It went smooth and I saved $625. 
112300 mi

US $326
CVT fluid leaks. Dealer replaced transmission output shaft seal. 
113000 mi

US $84
Engine cranks but doesn't start. Found CEL's P0700 and U2105. Replaced battery and reset CEL's. Engine cranks and starts normal. No CEL's. 

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2003 Saturn ION 4dr Coupe

264-horsepower 3.2L H6 4-speed automatic FWD

50700 mi

US $200
driver side wiper transmission needed to be replaced. 
52000 mi

US $200
O2 sensor and another sensor. 
60500 mi

US $204
Sway bar replacement (2) 
67000 mi

US $1400
Typical issue with Ions. 

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See TrueDelta's information for all Saturn models.

2005 Saturn ION Suspension Problems

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