Problems · NHTSA complaints

2004 Saturn Ion problems

Owners filed 898 complaints about the 2004 Saturn Ion with NHTSA between Jan 2004 and Nov 2025. The most-cited component is steering (345).

Complaints
898
Filed with NHTSA
Crashes
51
Reported by owners
Fires
4
Reported by owners
Injuries
35
People reported injured
Deaths
3
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Steering345
  2. Electrical system331
  3. Power train60
  4. Air bags52
  5. Fuel/propulsion system36
  6. Engine and engine cooling33
  7. Vehicle speed control27
  8. Exterior lighting25
  9. Engine23
  10. Suspension19
  11. Equipment17
  12. Fuel system, gasoline16
  13. Structure16
  14. Visibility13

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Nov 9, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
200433
200552
200623
200753
200874
2009112
2010152
201149
201248
201341
2014147
201545
201617
201717
201811
20198
20207
20213
20222
20233
20240
20251

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Steering

345 reports16 crashes1 fire1 related recall
“The car doesn't always want to release the key. I have to stick my finger up in the column to push the little button to release it which is not convenient at all. It seems to do it if the wheels aren't completely straight. But still even with the steering wheel straight, sometimes it wont come out if its on a slight hill. Ive had a new key made and it makes no difference, no check engine light and auto technician said the ignition looks fine. Ive read tons of reports like this on the 2004 saturn ion 2-why isn't this being addressed?”
Owner complaint to NHTSAFiled Nov 2, 2025SteeringODI 11696981

Electrical system

331 reports10 crashes3 fires2 related recalls
“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.”
Owner complaint to NHTSAFiled Jul 6, 2023Electrical system, Air bagsODI 11530643

Power train

60 reports2 crashes
“1. THE IGNITION SWITCH WILL NOT DISENGAGE...SOMETIMES AFTER MOTOR IS TURNED OFF AND CAR IS IN PARK THE CAR MUST BE TURNED BACK ON FOUR OR FIVE TIMES BEFORE THE IGNITION WILL ENGAGE CORRECTLY. THE VEHICLE IS STATIONARY...IN THE PARK POSITION....KEY WILL LOCK INSELF AND NOT DISENGAGE. THE CAR WAS ON A CITY STREET WHEN THIS OCCURRED. IT BEGAN TO OCCUR FIVE MONTHS AGO...NOW IT HAPPENS AT LEAST TEN TIMES A WEEK. 2. ALL ELECTRICAL SYMBOLS ON DASHBOARD SAY: COOLANT...BUT WHEN CHECKED THE COOLANT IS FINE.”
Owner complaint to NHTSAFiled Aug 22, 2017Power train, Electrical systemODI 11018943

Air bags

52 reports30 crashes1 related recall
“2004 SATURN ION. CONSUMER WRITES IN REGARDS TO AIRBAG SAFETY RECALL. CONSUMER STATES THAT THEY WERE NEVER NOTIFIED OF RECALL AND DURING AN AUTO ACCIDENT AIRBAGS DID NOT DEPLOY. *LD *TR”
Owner complaint to NHTSAFiled Oct 2, 2018Steering, Service brakes, hydraulic, Electrical system, Air bagsCrash reportedODI 11131268

Fuel/propulsion system

36 reports1 fire
“Hi I am a kind of new owner of an 04 saturn ion, this is actually the second complaint I've filled out. Last July I had a mechanic friend look at my fuel filter and he had said the fuel line needed to be cut off becuase of how rusted on to the original fuel filter I'd got it with was and I didn't believe him so I replace it myself and when I got it off I had cleaned up the metal fuel line the best I could and put a new filter on. Well now it leaks gas right where the hook up is and very strong fuel smells come from there too, I've gotten numerous comments about how un safe that is to be driving it but I need to have a way to work and then someone had mentioned to check for recalls and I seen on there that this car did have a recall for faulty fuel filter gas lines. If you could get back to me as soon as possible about an inspection if needed or whatever else you'd need on my behalf. Please and thank you for your time”
Owner complaint to NHTSAFiled Sep 11, 2021Fuel/propulsion systemODI 11432589

Engine and engine cooling

33 reports
“2004 SATURN ION. CONSUMER WRITES IN REGARDS TO ELECTRONIC POWER STEERING FAILURE. *SMD THE CONSUMER STATED SHE FIRST STARTED HAVING FRONT SUSPENSION PROBLEMS, WHICH THE DEALER FIXED FREE OF CHARGE. THE EXHAUST WAS LEAKING AND SHE PAID TO HAVE IT REPLACED, ALONG WITH THE CATALYTIC CONVERTER. ALSO, THE HORN STOPPED WORKING. THE CONSUMER RECEIVED A LETTER IN JULY 2012, FROM GM STATING THE WARRANTY WAS BEING EXTENDED BECAUSE THE ELECTRIC POWER STEERING COULD FAIL. ON DECEMBER 16, 2013, THE POWER STEERING FAILED, AS THE CONSUMER WAS LEAVING A PARKING LOT. SHE HAD TO USE EXTRA FORCE TO TURN THE STEERING WHEEL. AFTER A COUPLE OF MINUTES, IT WAS BACK TO NORMAL. A TEST REVEALED, THERE WAS INDEED A FAILURE. WHEN THE CONSUMER CALLED GM, SHE WAS INFORMED THE EXTENDED WARRANTY HAD EXPIRED ON 11/28/13 THE CONSUMER NO LONGER OWNS THE VEHICLE. UPDATED 02/5/14”
Owner complaint to NHTSAFiled Jan 9, 2014Suspension, Engine and engine cooling, Electrical system, SteeringODI 10558808
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 9, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.