NHTSA — Structure: Body: Door Problems

CarComplaints.com Seal Of Avoid Like The Plague

CarComplaints.com Notes: When it comes to the 2006 Ion, the biggest questions are: what big problem is going to pop up next? And how long until GM chooses to address it?

The 2006 Ion has a defective ignition switch that gave owners fits. Their keys would get stuck in the ignition, the engine wouldn’t shut off or in some cases it would shut off at the most dangerous time. The ignition was eventually recalled as part of one of the largest recalls of all-time , but it took GM 10 years to do it. Then there’s this car’s temperamental power steering which is prone to stop working randomly while driving. It too was eventually recalled, even if GM took their sweet time about it.

Lastly, it turns out a car built with plastic doors, fenders and bumpers – while fun for a game of “shopping cart bocce” – is horrible for safety.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
88,935 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2006 Saturn Ion body / paint problems

body / paint problem

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2006 Saturn Ion Owner Comments

problem #6

Jun 112015


  • 80,000 miles


The contact owns a 2006 Saturn Ion. When the vehicle was turned off and the key was removed from the ignition switch, a beeping sound was heard. The contact had to close the doors in order for the beeping sound to stop. The contact stated that the driver's side door failed to lock with the remote. The contact had to manually lock the driver's side door. The failures occurred without warning. The dealer (O'rielly Chevrolet Inc., 6160 E broadway blvd, tucson, AZ 85711) was contacted and stated that the contact had to pay to have the vehicle diagnosed. The vehicle was not taken to the dealer. The vehicle was not diagnosed or repaired. The manufacturer was contacted at 800-553-6000 and stated that they could not do anything. The contact was advised to call NHTSA. A case number was not provided. The approximate failure mileage was 80,000.

- Tucson, AZ, USA

problem #5

Jun 022014


  • 127,000 miles
The contact owns a 2006 Saturn Ion. The contact stated that the driver side door failed to open or shut and all the power windows failed to operate. The dealer was not able to open the driver side door and could not continue servicing the vehicle. The manufacturer was notified of the failure. The approximate failure mileage was 127,000.

- Moreno Valley, CA, USA

problem #4

Apr 012014


  • 134,000 miles
The contact owns a 2006 Saturn Ion. The contact stated that the front driver side door was unlocked but the door could not be opened. The vehicle was taken to an independent mechanic who diagnosed that the locking mechanism was defective. The vehicle was not repaired. The manufacturer was notified of the defect. The failure mileage was 134,000.

- Rossville, GA, USA

problem #3

Aug 112013

Ion 4-cyl

  • 88,000 miles


Neither the external or internal door handles will allow one or more doors to open. My drivers side door just stopped working from the external/internal door handles. In the event of an emergency where I might need to get out of my car in a timely manner it will not be possible as I would have to climb over to the passenger side to get out. If something bad happened and both doors had the same problem around the same time someone might have to crawl out the cars windows in order to get out. In the extreme something happened to the electrical system and both doors at the same time you could be trapped in your car until rescue personal arrived. Seems to me that there should not be a single point of failure on a door handles that would cause both the external and internal handles to no longer function as required and cause the door to open. I have done web searches for this and it appears to be a common problem. The fix is you have to take it to someone that could spend upwards of 4 or more hours to get the door opened before they can even start to fix the problem. If GM/Saturn can't correct the problem in an acceptable manner then should at least cover the cost of fixing the problem every time it happens.

- San Francisco , CA, USA

problem #2

Dec 142010


  • 74,612 miles
The contact owns a 2006 Saturn Ion. The contact stated that the vehicle was taken to a local repair shop for a failure with the driver side door and when the mechanic attempted to turn the engine off, it would not shut off. The mechanic had to disconnect the battery which shut down the fuel system and computer system. The mechanic reprogrammed the computer, key code pass system, replaced the ignition and the driver side door motor. The ignition repair did not correct the problem. The contact called the manufacturer and filed a complaint. The failure mileage was 74,612 and the current mileage was approximately 75,000. Updated 03/24/11 updated 12/30/11

- Daphney , AL, USA

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problem #1

Nov 192008


  • 30,000 miles
The contact owns a 2006 Saturn Ion. The contact was driving approximately 5 mph with a sudden loss of power steering. The power steering warning light indicator illuminated. There was extreme difficulty steering the vehicle. The vehicle was taken to an independent mechanic for diagnostic testing. The power steering motor and steering column would need to be replaced. In addition, the front passenger door would stick unless body pressure was applied to the door. The vehicle had not been repaired at the time of the complaint. The failure mileage was 30,000. The VIN was unavailable.

- Sonoma, CA, USA

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