This bulletin provides information on the harmful effects of water or ethylene glycol in transmission fluid.
full bulletin at NHTSA ↗2006 Saturn Ion powertrain problems
moderate 25 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Failure mileage
Complaints
25
Recalls
0
Avg fix
$2,500
When does it fail?
Of the 25 powertrain complaints filed for the 2006 Saturn Ion, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 25 powertrain complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA powertrain complaint has been filed on this vehicle in over 11 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering powertrain on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This PI bulletin advises the technician on the proper way to install the pistons in an engine.
full bulletin at NHTSA ↗This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns.
full bulletin at NHTSA ↗This bulletin provides information on the harmful effects of water or ethylene glycol in transmission fluid.
full bulletin at NHTSA ↗This service bulletin provides information on OEM and Remanufactured Engine and Automatic Transmission/Transaxle Identification.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 Saturn Ion powertrain shows multiple distinct failure patterns. The most common complaint is manual transmission difficulty engaging gears, especially first gear when cold or overnight. Owners report the car lurches forward unexpectedly when restarted and works normally after sitting idle for 5–7 minutes. Dealers decline warranty repair, often citing lack of trouble codes.
Ignition switch failure is widespread. Keys stick in the ignition after shutdown; in severe cases the engine keeps running even after turning off the key. Owners have had to disconnect batteries to stop electrical drain. Repair costs run about $400 for ignition lock replacement.
Unexpected engine shutdown during deceleration, turns, or parking maneuvers is documented repeatedly. Owners report the car stalls 3–4 times backing out of parking spaces and must restart multiple times to leave. No warning lights appear before most of these failures.
Automatic transmissions fail without warning—one vehicle downshifted from 65 mph to 30 mph, then refused to move forward. Another lost reverse gear at 35,000 miles. Power steering cuts out intermittently or completely, especially during parking, and the problem worsens over time.
Accelerator pedal stuck fully depressed on highway; hard starting requiring 2–10 minutes of cranking; and vehicle reversing on its own without the key in the ignition are also reported. Dealers routinely refuse diagnosis and repair without trouble codes, leaving owners stranded with high repair estimates.
Same Saturn Ion powertrain reports on nearby years: 2005 · 2007
Failure modes owners describe
Difficulty engaging gears, especially first gear when cold
Manual transmission vehicles experience trouble going into first gear from neutral when the car is cold or sitting overnight. Owners report the car must be turned off and restarted, with a characteristic lurch forward when ignition is turned back on. Gear shifts become easy after idling or sitting for several minutes.
When: Cold start; intermittent, recurring daily for some owners; 18 miles to 96,000 miles
Symptoms owners cite: Unable to engage first gear from neutral when engine is running; Car lurches forward unexpectedly when ignition is turned on; Gear shift becomes stiff or unresponsive; Transmission slips or grinds when shifting; Problem clears after car sits idle for 5–7 minutes
Codes mentioned: No trouble codes generated; dealers refused to diagnose without codes
Repairs/costs cited: Owners suspect clutch master cylinder or transmission internal failure. One dealer quoted $115 diagnostic fee. One independent mechanic diagnosed fractured clutch requiring replacement. Service bulletins mentioned but dealers refused to repair without trouble codes.
Recalls/TSBs owners mention: Dealers declined warranty repair. One service manager refused to work on vehicle until problem occurred in front of their technician. Saturn Customer Service and corporate office sided with dealers.
Stuck ignition key and inability to shut off engine
Ignition switch fails to release the key after engine shutdown. In severe cases, engine continues running even after turning the ignition off; key cannot be removed and electrical systems remain powered. Some owners had to manually disconnect the battery to stop the engine.
When: Intermittent to frequent; begins less than 6 months after purchase; 18 miles to 96,000 miles
Symptoms owners cite: Key stuck in ignition switch and cannot be removed; Engine continues running after ignition turned to off position; Electrical systems remain on when engine is off; Requires jiggling the key to shut off engine; Vehicle lurches or shakes when attempting to restart with stuck key
Repairs/costs cited: Dealers performed multiple lubrication attempts without lasting fix. Ignition lock replacement cost approximately $400. One owner had to stall engine by popping clutch, then disconnect battery to stop electrical drain.
Recalls/TSBs owners mention: Defective shifter switch safety recall issued. Manufacturer reimbursed one consumer for repair after contact. Most dealers reluctant to replace ignition switch or transmission/gear shift mechanism under warranty.
Unexpected engine shutdown while driving
Engine stalls during normal driving operation, particularly when slowing down, turning, backing out, or coming to stops. Problem begins around 18 miles on one vehicle and recurs multiple times during parking maneuvers. Power steering warning light may appear before shutdown.
When: Intermittent; 18 miles to 87,000 miles; occurs when decelerating or turning
Symptoms owners cite: Engine shuts off without warning during deceleration or turns; Vehicle stalls 3–4 times when backing out of parking spaces; Power steering warning light may illuminate before shutdown; Restart required multiple times to leave parking area; Occurs while slowing down behind other vehicles
Repairs/costs cited: One dealer suspected power steering module or steering wheel-related component. Diagnostic test quoted at $100. No repairs completed; owners defer due to fear of high repair costs.
Recalls/TSBs owners mention: No recalls issued despite multiple complaints describing similar pattern. Owners report reading other complaints online with identical symptoms.
Ignition module, switch, coil, and harness failure
Ignition system components fail, causing startup difficulty, strange noises, and severe engine limp mode. Repair required replacement of ignition module, switch, coil, and harness together.
When: Early in vehicle ownership; one vehicle required repair after initial purchase
Symptoms owners cite: Trouble starting engine; Strange sounds during startup; Check engine light illuminated; Vehicle limited to 25–30 mph maximum speed; Engine cannot be shut off normally after failure
Codes mentioned: Check engine light
Repairs/costs cited: Saturn dealer identified issue as common problem with this make and model. Repair cost just under $800 for ignition module, switch, coil, harness. Vehicle remained in garage after repair due to suspected transmission damage.
Recalls/TSBs owners mention: Dealer advised this is a known common problem with thousands of complaints; GM aware but has not recalled due to company reorganization.
Transmission failure or severe degradation
Automatic transmission loses power to move the vehicle without warning. One vehicle downshifted unexpectedly from 65 mph to 30 mph, then refused to move forward in any gear. Another transmission failed completely at low mileage with no prior warning signs.
When: 61,000 miles (one case); 2 days after purchase (another case)
Symptoms owners cite: Transmission downshifts abruptly from highway speed; Vehicle loses all forward or reverse motion; No warning lights or signs before failure; Grinding noise during failure
Repairs/costs cited: One owner's transmission was diagnosed as completely failed. Another transmission was replaced free of charge by dealership (Jay Wolfe Saturn, Tiffany Springs, Missouri).
Recalls/TSBs owners mention: One owner contacted Saturn directly about sudden downshift hazard. No manufacturer response documented in complaints.
Loss of reverse gear
Transmission loses reverse gear capability or slips when shifted into reverse. Can occur at low mileage with no warning signs.
When: 35,000 miles; intermittent initially
Symptoms owners cite: Abnormal grinding sound when shifting to reverse; Vehicle slips or fails to engage reverse; Unable to shift gears smoothly
Repairs/costs cited: One dealer could replicate problem manually but could not generate trouble code. Service bulletin issued but dealer refused repair under warranty without trouble code. One owner reported transmission replaced free of charge by dealer.
Recalls/TSBs owners mention: Service bulletin issued. Dealer and Saturn Customer Service both refused warranty repair without trouble code. Customer told to continue driving until problem worsens enough to generate code, at which point vehicle would be out of warranty.
Stuck or sticking accelerator pedal
Accelerator pedal becomes fully depressed and stays pressed even after driver's foot is removed. Occurs during highway merge in one case; pedal fails to return to idle position.
When: 60–70 mph highway driving during merge
Symptoms owners cite: Accelerator pedal stays fully depressed after foot removed; Pedal does not return to default position; Vehicle continues accelerating despite foot off pedal; Braking required to slow vehicle while in neutral
Repairs/costs cited: Owner was able to release pedal by depressing it hard while in neutral. No repair documented.
Accelerator failure causing power loss
Vehicle fails to accelerate when pedal is depressed at highway speed, resulting in loss of power and inability to maintain speed.
When: 35 mph (one case); 50,000 miles
Symptoms owners cite: Vehicle fails to accelerate when pedal depressed; Dragging sensation and deceleration when attempting to shift gears; Grinding noise from transmission; Prolonged starter cranking before ignition (over 10 minutes in one case)
Repairs/costs cited: Dealer unable to diagnose cause. Vehicle towed and remained at dealer. No repairs documented.
Gear shift button comes loose or falls off
The button that must be depressed to release the gear shift can come off. Replacement button may not stay seated and can fall off again, creating potential traffic hazard.
When: During normal operation
Symptoms owners cite: Gear shift release button detaches; Button falls off after replacement; Difficulty keeping button properly aligned
Repairs/costs cited: Button can be replaced but does not stay seated reliably.
Vehicle shifts into reverse on its own without key in ignition
Transmission unexpectedly shifts vehicle into reverse without ignition key present after gear shifter is struck accidentally.
When: 86,000 miles
Symptoms owners cite: Vehicle reverses independently after shifter accidentally struck; No ignition key in switch
Recalls/TSBs owners mention: Manufacturer notified. No repair or diagnosis documented.
Power steering system failure
Power steering cuts out intermittently or completely during normal driving, making steering difficult or impossible. May be accompanied by warning light or audible groaning. Problem worsens over time and eventually occurs on every startup.
When: 2008 (for one vehicle that started with problems in 2006); occurs increasingly frequently; 36,000 miles in 5 years on one lease vehicle
Symptoms owners cite: Power steering goes out during driving or parking maneuvers; Power steering warning light illuminates intermittently or constantly; Groaning or noise from power steering system; Steering becomes very heavy and difficult; Problem occurs more frequently over time; eventually happens immediately upon startup
Codes mentioned: Power steering warning light
Repairs/costs cited: Fluid level checked and found adequate. One dealer suspected power steering module. No repairs completed; owners defer due to cost concerns or warranty expiration.
Recalls/TSBs owners mention: Dealers state no recall exists. Multiple online complaints document identical issue. One leasee was told vehicle is out of warranty despite only 36,000 miles in 5 years.
CV driveshaft failure (high-performance Redline model)
CV driveshaft fails on the high-performance Redline model variant of the 2006 Saturn Ion.
When: <UNKNOWN>
Symptoms owners cite: CV driveshaft failure
Repairs/costs cited: Not covered under GM warranty.
Hard starting or extended cranking time
Engine takes extended time to start, ranging from 2 to 10 minutes, or fails to reach run position. Check engine light may be illuminated.
When: Intermittent; documented on vehicles with recalls and without
Symptoms owners cite: Car will not go into run position; Delayed start requiring 2–10 minutes of cranking; Check engine light illuminated; Occasional normal starts mixed with extended crank times
Codes mentioned: Check engine light
Repairs/costs cited: Battery tested and found acceptable. Alternator tested and found acceptable.
Recalls/TSBs owners mention: Owner mentions anticipation of a recall fix related to this problem.
Electrical system malfunction triggered by bumps in road
Electrical system reacts as though vehicle has been in a collision when driving over bumps, cutting motor and displaying false airbag deployment warning.
When: 30 mph over a bump
Symptoms owners cite: Engine cuts out when driving over bumps; Airbag deployment warning displayed (false alarm); Electrical system reset after several minutes
Codes mentioned: Airbag deployment warning
Repairs/costs cited: Vehicle restarted fine with no adverse effects after waiting.
Recalls/TSBs owners mention: Dealer reported never having heard of this issue and unable to explain cause.
Synthesized from 25 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Tl* the contact owns a 2006 Saturn ion. The contact stated that the gear shifter was accidentally struck and the vehicle reversed independently without a key in the ignition. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 86,000.
Had powertrain trouble with your 2006 Saturn Ion?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the powertrain problem on the 2006 Saturn Ion?
It's a documented issue but not catastrophic. 25 complaints have been filed. Repairs average $2,500 and most owners catch it before it causes a breakdown.
At what mileage does the powertrain typically fail?
Across the 21 complaints that reported odometer mileage, most powertrain failures cluster between 45,000 and 86,000 miles, with the median around 56,545. A quarter of owners report trouble before 45,000; a quarter make it past 86,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $2,500 for powertrain repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to powertrain?
No active recalls currently cover powertrain issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Saturn/Ion.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.