One problem related to front suspension control arm has been reported for the 2004 Saturn ION. The most recently reported issues are listed below.
At approximately 3:50 p. M. Friday January 23 2015 I was slowing down from 35 mph to turn into a parking lot. Before I turned the passenger side of the car dropped and at first I thought I blew a tire. After limping the car into the parking lot I got out and the tire was still fully inflated. I noticed the lower control arm was broken into two pieces. The car was towed home and the tow truck driver even mentioned he had never seen that happen on such a new vehicle.