Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Saturn Ion owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle stalled. Additionally, the contact stated that the key was stuck in the ignition. The failure was intermittent. The vehicle was taken to the dealer, who replaced the ignition switch and the ignition lock cylinder; however, the failure recurred. The contact stated that while driving at an undisclosed speed, the vehicle stalled. The contact related the failure to NHTSA Campaign Numbers: 14V047000 (Air Bags, Electrical System) and 14V171000 (Electrical System). The manufacturer was made aware of the failure. The failure mileage was approximately 230,000.
Was guaranteed that nothing was wrong with it. I originally got a 2007 Ford escape by trading in my vehicle and 500 cash. They wanted me to put down an additional 900 down which I ended up not being able to do. So they offered to put me in another vehicle that was cheaper and I would not have to put any more money on. The 2004 Saturn Ion I received on 08/23/2016 not only had clutch issues which I said I would fix, but the battery light kept coming on and they assured me that nothing was wrong with the car mechanically. We did not even make it down the road before the vehicle broke down and had to have it towed. So now the car sits in my yard and I am out my original vehicle and the 500 cash I used originally plus towing charges and a vehicle I have to pay on that I cannot drive. I want them to come get the car and give back the 500 I wasted on two junk vehicles. …
March 2015 - dealership replaced the recalled ignition. Shortly after the car wouldn't start a few times, and I replaced the starter. June-July 2016 - the car wouldn't start and the passlock light would turn on. After resetting the passlock (leave the ignition turned to the run position for 10 minutes) it would start imediately. July 11, 2016 - taken to the same dealership and told them it started after the ignition was changed. Told that it was the body control monitor ($829). Repairs finished July 15, 2016. August 4, 2016 - car taken back for trouble starting once more. August 8, 2016 - ignition changed once more, but charged again because GM wouldn't cover it. I find it ridiculous that my car worked fine until I had a part changed due to a recall, and now that replacement was faulty and I'm being charged for it!
Tl* the contact owns a 2004 Saturn Ion. The contact stated that while entering a parking lot at 3 MPH, the vehicle suddenly stalled and the contact crashed into a cement pillar. There were no injuries. The vehicle was to be repaired under NHTSA campaign number 14V047000 (air bags, electrical system) but was informed that the part was not yet available. The vehicle was not diagnosed or repaired. The manufacturer was not contacted about the failure. The failure mileage was 87,000. Updated 06/10/14 ma the consumer stated he lost power steering, and the vehicle surged forward into a concrete pillar. The ar bags did not deploy. The consumer stated the bumper absorbed the hit, and there was no real damage. Updated 07/24/14
Tl* the contact owned a 2004 Saturn Ion. While driving approximately 62 MPH, the vehicle stalled and came to a sudden stop as the contact attempted to exit the freeway. The vehicle rolled over two times and landed upside down. The air bags failed to deploy. The contact sustained injuries that required medical attention. A police report was filed. The vehicle was destroyed and towed to a body shop. The manufacturer was made aware of the failure. The contact notices for NHTSA campaign numbers: 14V047000 (air bags, electrical system), 14V171000 (electrical system), and 14V153000 (steering) after the crash occurred. The failure mileage was unavailable.
Tl* the contact owns a 2004 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle loss power steering without warning. The contact turned off and restarted the vehicle and the vehicle operated as intended. Additionally, the windows rolled up and down independently. The contact also stated there was an abnormal fuel outside the vehicle. The vehicle was not taken to be diagnosed. A dealer was not contacted however, the manufacturer was made aware of the failure. The contact was referred to the local dealer to have the vehicle diagnosed. The vehicle was not repaired. The failure mileage was 172,639.
2004 Saturn Ion 2 the ignition switch turned off numerous times on me, and the power steering went out probably 10 times a week. The consumer stated he was able to remove the key from ignition, at any time in any gear. The consumer was involved in two accidents due to the vehicle shutting off, during a turn. The second accident occurred in February 2014. While attempting to make a turn, he soon discovered the vehicle had no power steering and was unable to steer the vehicle. Consequently, he ran off the road and struck the right edge of a driveway. The ignition lock cylinder was replaced on September 12, 2014.
Tl contact owns a 2004 Saturn Ion. The contact stated that while driving at approximately 45 MPH, the power steering failed and the vehicle failed to accelerate without warning. The vehicle was towed to the dealer where it was diagnosed that the ignition switch needed to be replaced. The contact mentioned that other unknown repairs were performed. The vehicle was repaired but the failure recurred. The manufacturer was notified of the failure. The approximate failure mileage was 72,000. ... Updated 03/19/15 updated 9/20/2017
While driving in pre-dawn hours (headlights & defrosters on), started smelling something melting or burning. Then instrument panel lights went out for a few seconds. Instrument panel lights then came back on & started flashing on & off really fast. At that same time, door locks started locking & unlocking repeatedly on their own. Burning & melting smell was getting stronger. As I was pulling over, I entered a more well-lit area and saw smoke accumulating inside car near roof & top of windshield. Shut car off immediately.
Tl* the contact owns a 2004 Saturn Ion. When attempting to start the vehicle, it failed to start. The contact mentioned that the failure was intermittent. The vehicle was towed to an independent mechanic three times and the battery and crank sensor were replaced, but the failure recurred. The vehicle was not taken to a dealer or independent mechanic for diagnostic testing. The vehicle was not repaired. The manufacturer was not made aware of the failure. The VIN was not provided. The failure mileage was approximately 130,000.
Related 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.
Remedy: General Motors will notify owners, and for vehicles that were built with the defective ignition cylinder and have not previously had the ignition cylinder replaced with the redesigned part, dealers will replace the…
Electrical complaints in other Ion years
Frequently asked questions
How common are electrical problems on the 2004 Saturn Ion?
NHTSA has 331 complaints about the electrical system of the 2004 Saturn Ion, 37% of the model year's 898 complaints. The component named most often is ignition (47 mentions).
Is there a recall for 2004 Saturn Ion electrical problems?
Yes — NHTSA recall 14V-171 (ignition, Apr 10, 2014). Recall repairs are free at authorized dealers.
At what mileage do 2004 Saturn Ion electrical problems start?
Half of the complaints with a recorded mileage happened before about 54,000 miles, and 16% before 25,000 miles.
Is it dangerous?
Owners linked 10 crashes, 3 fires and 8 injuries to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.