This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
full bulletin at NHTSA ↗2007 Saturn Ion electrical problems
severe 160 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
160
Recalls
0
Avg fix
$850
5crashes
5injuries
When does it fail?
Of the 160 electrical complaints filed for the 2007 Saturn Ion, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 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 160 electrical 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.
Electrical accounts for 18% of all owner complaints filed against this vehicle, across 12 categories tracked.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical 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 Preliminary Information communication provides information to the technician about vehicles that have an intermittent no crank, no start, or start stall concern with the security light coming on. Technician may find Diagnostic Trouble Codes B3055, B3060, and/or B3935. Technician should not replace any parts for this concern. If unable to duplicate the concern ask if the customer uses any Radio Frequency Identification Devices when the concern is present. Dealer should also direct their customers to the appropriate section in the Owner manuals that references that the device complies.
full bulletin at NHTSA ↗Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
full bulletin at NHTSA ↗This bulletin provides information on identifying Non-GM Engine Calibrations for Gasoline Engines using the Tech 2 or GDS 2.
full bulletin at NHTSA ↗This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The dominant failure across 160 complaints is an ignition key that gets stuck and won't turn to OFF or remove from the cylinder, leaving the car running with the driver trapped. Owners routinely disconnect the battery or pull fuses under the hood to shut down the car. The condition shows up sporadically—sometimes intermittent over months, sometimes suddenly locked solid—across vehicles with mileage from under 5,000 to over 165,000 miles.
GM issued Recall 14V-047 in March 2014 for the ignition switch, but owners report parts backlogs lasting 2–3 months. More troubling: many describe the same key-stuck failure recurring within weeks or months after the recall repair. A secondary pattern emerges where the automatic shift lock solenoid fails to register PARK, preventing key removal; dealers quote $400+ for the solenoid but claim it's the owner's bill, not covered under recall.
Owners also report airbag warning lights coming on after recall work, and two documented crashes where airbags failed to deploy. Electrical faults appear after ignition repair—radio and windows glitching, power steering suddenly failing mid-drive, seat belt warning lights flashing. One owner detected excessive trunk moisture and exhaust fumes near the gas tank via a defective one-way vent valve. Throughout, dealership service has been inconsistent: some acknowledge the problem as widespread, others deny it exists or blame the owner.
Same Saturn Ion electrical reports on nearby years: 2005 · 2006
Failure modes owners describe
Ignition key stuck in ignition / key won't turn or remove
The ignition key becomes stuck and will not turn to the OFF position or release from the cylinder. The engine continues to run, trapping the driver in the vehicle with doors locked. Owners must disconnect battery or pull fuses to shut down the car. The condition is intermittent or chronic and often recurs even after dealer or independent repair.
When: Occurs across various mileages from under 5,000 miles to over 165,000 miles. Can happen at any time—when parking, after driving, or on first start.
Symptoms owners cite: Key will not turn from ON/ACC to OFF position; Key cannot be removed from ignition cylinder; Car remains running with key stuck; Doors lock and will not unlock; Key is stuck in ACC position only; Condition is intermittent, happening sporadically over weeks or months
Repairs/costs cited: Dealer/independent shops replace ignition cylinder and/or ignition switch. Costs range from $230 to $900+ depending on labor and parts. Some owners report battery discharge ($205 new battery) while waiting months for recall parts. Issue often recurs after repair.
Recalls/TSBs owners mention: GM Ignition Switch Recall 14V-047 (2014). Owners report long delays (2–3+ months) waiting for recall parts. After recall work, many report the same or related failures (key sticking, door lock issues) persist. Dealerships initially denied this was a known issue or recall despite widespread online complaints dating back years.
Gear shift / shift lock solenoid not engaging properly
After ignition switch recall repairs, the automatic gear shift fails to register the PARK position, preventing the key from being released. Owner must repeatedly start and shift the vehicle multiple times to force the solenoid to engage before the key will turn OFF and come out.
When: Begins after or during ignition switch recall repair. Mileage varies.
Symptoms owners cite: Gear shift will not engage or disengage properly; Shift lock solenoid does not register PARK position; Key cannot be removed until vehicle is restarted multiple times; Key gets stuck in ignition until shifting sequence is repeated
Repairs/costs cited: Dealers quote $400+ to replace shift lock solenoid. Owners report dealer claiming this is 'remotely connected' to recall but billing customer instead of honoring recall coverage.
Recalls/TSBs owners mention: Recall work acknowledged. Dealerships claim solenoid replacement is customer responsibility even though it appears to be a consequence of ignition recall repair. GM initially denied parts were covered, then began ordering parts 'by VIN' under revised recall protocol, causing further delays.
Airbag warning light illumination / airbags fail to deploy
Airbag warning light illuminates intermittently on the dashboard after ignition switch recall work. In two crash scenarios, airbags failed to deploy despite front-end impact and rear-end collisions at 50+ mph.
When: Begins within 2 months after ignition recall repair; mileage 27,600 and 43,000; crash events October 2016 and December 2017.
Symptoms owners cite: Airbag warning light stays on or flashes intermittently; Light turns on and off randomly during startup or while driving; Airbags do not deploy in collisions (50–65 mph impacts); Light frequency increases after second recall repair
Repairs/costs cited: No repairs documented. Dealers inform owners the recall work was unrelated to airbag failure. Owner sustained chest and head injury in crash where airbags failed to deploy.
Recalls/TSBs owners mention: Recall 14V-047 listed as related to electrical system and airbags. Dealership states recall remedies had nothing to do with reported failures.
Engine stalling / loss of power while driving
Vehicle suddenly loses power and decelerates from highway speeds to 0 mph, or stalls intermittently. Engine light illuminates. Vehicle jerks and hesitates. Condition occurs repeatedly despite dealer diagnostics and sensor replacement.
When: Occurs across various mileage points: 11,000–13,000 miles (early), and ongoing. One incident at unknown mileage in 2017.
Symptoms owners cite: Sudden deceleration from 55 mph to 30 mph, then to 0; Engine stalls without warning; Check Engine light illuminates; Vehicle jerks and hesitates until reaching 30 mph; Multiple stalls in short distance (25 miles)
Codes mentioned: Ignition Switch fault code (reported by owner after check engine light)
Repairs/costs cited: Dealer replaced accelerator pedal sensor but issue persisted. Dealer twice stated 'nothing is wrong.' One owner reported $2,000 estimate for cylinder 1 misfire after ignition recall work. Another technician blamed ignition switch design.
Recalls/TSBs owners mention: No recalls for this specific failure. After ignition switch recall, one owner's check engine light indicated ignition switch fault; dealer quoted $80 for part, $150 programming, $150+ labor.
Power steering failure
Power steering suddenly fails while driving, leaving the steering wheel locked or immobile. Vehicle becomes difficult or impossible to control.
When: Occurred on highway after ignition recall repair; another incident while reversing in parking lot.
Symptoms owners cite: Power steering abruptly fails mid-drive; Steering wheel locks or becomes immobile; Unable to turn the wheel; Problem resolves briefly after restarting vehicle (in one case); Failure described as 'very scary' on highway
Repairs/costs cited: One owner obtained rental car for 1 month during repair. Another incident in 2017 while reversing; steering seized and vehicle stalled; ignition key independently released from switch; GM dealer replaced locking system and ignition key but failure recurred.
Recalls/TSBs owners mention: Covered under separate recall (separate from ignition recall). Dealer replaced part and provided rental. Failure recurred post-repair.
Electrical system intermittent failures (radio, windows, door locks)
Radio turns on/off by itself with display flashing; windows stop working then resume; door locks fail to engage when shifting into drive. Issues appear related to body module or electrical harness.
When: Ongoing for several months; one incident after ignition/steering column recall work.
Symptoms owners cite: Radio powers on and off unpredictably; Radio display flashes patterns, difficult to determine on/off state; Power windows intermittently fail; resume after car restart; Door locks do not engage when vehicle shifted into DRIVE; Power steering loss correlates with electrical symptoms
Repairs/costs cited: Owner's sister had similar issue on Saturn Vue; her body module was replaced and eventually car would not start. No parts or repairs documented for this Ion.
Recalls/TSBs owners mention: No specific response mentioned. Dealer replaced steering column and ignition as part of recall; electrical gremlins persisted.
Trunk moisture / one-way flapper valve leak
Excessive moisture accumulates in trunk, detected via desiccant saturation within 2 weeks (vs. 2 months in a house) and carbon monoxide monitor showing peak level 10 after 24 hours. Mud-like residue found inside trunk on passenger side, traced to defective one-way flapper vent/valve (approximately 4×6 inches). Valve is located near gas tank filler cap, 12V battery, and fuel system.
When: Detected early 2013; moisture noted May 2013; fume detection and source identification June 2013.
Symptoms owners cite: Visible moisture and clumping in trunk; Muddy residue on interior trunk wall passenger side; Rapid saturation of commercial desiccant (DAMP RID); Carbon monoxide monitor chirping after 24 hours (peak level 10); One-way flapper valve malfunctioning
Repairs/costs cited: Owner cleaned trunk and documented defect. No dealer repair documented.
Recalls/TSBs owners mention: No manufacturer response documented. Proximity to fuel tank, battery, and exhaust raises corrosion and explosion risk.
Vehicle fails to start / key will not turn in ignition
Vehicle randomly refuses to start; the ignition key will not turn in the lock. Condition is unpredictable and occurs in both warm and cold weather. Waiting 20 minutes sometimes allows restart, but often does not. Dealer has replaced ignition switch and fuse; problem persists.
When: Can happen on first start of the day or after shutdown. Multiple stranding incidents reported in freezing and extreme heat.
Symptoms owners cite: Key will not turn in ignition cylinder; Vehicle will not start; Condition is completely unpredictable; Intermittent; sometimes resolves after waiting 20+ minutes; Owner and child stranded in freezing temps and extreme heat on multiple occasions
Repairs/costs cited: Dealer replaced ignition switch and fuse; issue continues.
Recalls/TSBs owners mention: No specific recall or coverage documented for this start-only failure (distinct from key-stuck-in-ON issue).
Seat belt warning light intermittent / seat belt detachment
Seat belt warning light illuminates intermittently on dash (on/off randomly) after ignition recall. In one crash, front driver's side seat belt unexpectedly detached, causing driver to strike dashboard and sustain chest and head injury.
When: Light issues begin within months after ignition recall work (post-May 2014). Crash/detachment event June 2014 at 27,600 miles during low-speed reverse collision.
Symptoms owners cite: Seat belt warning light stays on or flickers; Light illuminates randomly at startup or while driving; Front driver's side seat belt detached during crash; Driver struck dashboard, sustaining chest and head injury
Repairs/costs cited: No repairs documented.
Recalls/TSBs owners mention: Recall 14V-047 listed as covering airbags and electrical system. GM denies seat belt warning light is related to ignition recall work. Owner disputes; no detachment issues prior to recall.
Check Engine light / multiple sensor faults post-recall
Check Engine light illuminates, sometimes flashing warning lights and dashboard messages (COOLANT, TRUNK, TRACK, etc.) in mileage display. Vehicle may not start normally; takes 10+ minutes before mileage display appears and car will start. Sometimes requires 20+ seconds in OFF position before start is possible. Codes indicate ignition switch fault.
When: Occurred after ignition recall work; mileage varies.
Symptoms owners cite: Check Engine light on; Dashboard warning messages flash (COOLANT, TRUNK, TRACK, etc.); Car will not turn over or try to start initially; Flashers flash, then mileage display pauses 10+ minutes; Car requires reset (OFF position 20+ seconds) before restart
Codes mentioned: Ignition Switch fault code
Repairs/costs cited: Dealer quoted $80 for ignition switch part, $150 programming, $150+ labor (total $380+). Owner unable to pay; cited safety concern that vehicle might not start in emergency.
Recalls/TSBs owners mention: No coverage; customer billed for diagnosis and repair.
Synthesized from 160 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
The car failing to start on the first ignition cycle and a smell of fuel while driving and after the car as turned off was noticed. A week later fuel is now considerably leaking from near the rear of the car. A recall has been issued for a fuel pump problem on the 2007 ion, but only in certain states, illinois not included. Obviously, this is a major safety issue and yet another defective…
Tl*the contact owns 2007 Saturn ion. The contact stated that the key was stuck in the ignition and she was unable to turn the vehicle off. She also disconnected the battery and the vehicle would not shut off. The vehicle was not repaired. The failure and current mileages were 71,000.
I parked the car in front of my house, leaving the headlights on. When I went to put it in the garage, I turned the key in the ignition switch, and heard no sound. I realized I had left the headlights on and the battery was dead. Then the key would not turn in the lock so I could remove it. I could not open the trunk with the button on the dash, in order to replace the battery. The car is now…
Had electrical trouble with your 2007 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 electrical problem on the 2007 Saturn Ion?
It's a meaningful issue. 160 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 116 complaints that reported odometer mileage, most electrical failures cluster between 46,368 and 102,000 miles, with the median around 65,513. A quarter of owners report trouble before 46,368; a quarter make it past 102,000. 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 $850 for electrical 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 electrical?
No active recalls currently cover electrical 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/2007/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.