One problem related to engine exhaust system has been reported for the 2004 Saturn ION. The most recently reported issues are listed below.
2004 Saturn Ion. Consumer writes in regards to electronic power steering failure. 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.