Two problems related to steering rack and pinion have been reported for the 2006 Saturn ION. The most recently reported issues are listed below.
My Ion has had continuous steering and suspension problems since 2009. I have experienced the problems with the steering motor (warning light comes on - loss of power steering) and had the steering motor replaced. I have replaced the sway bar, control arms, link, and much more. And, I still have difficulties steering - have a constant cluncking noise from the front end and now have been told I need the rack & pinion replaced - estimated cost $550. The vehicle currently has 82,000 miles. The steering & suspension problems began immediately after the vehicle hit 50,000 miles.
I bought my 2006 Ion brand new with only 10 miles on it now the car is at 27k miles and now it has a clunking noise in the front suspension, I have taken in to dealer many times they have replaced 1) intermediate shaft 2) lower control arm rear bushing 3) catalytic converter 4) steering rack: and on top of all this it has been 8 months and my car is still not fixed. The dealer told me they don't know what it is. I have done some research found TSB's for this both of which they have supposedly already done.