Try pulling the steering wheel back and forth while trying to take the key out. Or, push forward and back on the shifter while it's in park, while trying to take the key out. This could be the steering wheel lock mechanism.
If you think it needs lubrication, try a LITTLE bit of graphite lubricant. Do NOT use WD-40.
SOURCE: saturn ion,sometimes wont start
The problem is in the ignition - the grease gets thick in the cold and doent turn quite right the first time. everything turns on, but the anti theft system thinks you have the wrong key so shuts off pwer to the starter. it takes 8-10 mintues to reset. That is why it normally starts when you come back later. I have had the same problem and done tons of reseach. Right now my temp solution has been a small heater and an extention cord. I keep it plugged in over night on a medium setting - just enough to keep the inside temp above freezing. I am also researching remote starts because saturn dealership charges $250 to replace the ignition, and a remote start will run about $300. Saturn wont do a recall because they feel it is not a safety hazard. I say that is bull. Good luck!
SOURCE: key stuck at ACC position
A bit too late to help you I know, but this may help others. The problem is most likely a small lever arm microswitch that is oriented with the lever arm DOWN located just beneath the drivers side of the shifter. This is an interlock switch which prohibits starting the Ion in anything but park or neutral. There is nothing that holds the switch on the two posts that it mounts on and it is quite awkward to put back on. I strongly recommend using a small strip of double sided 3M tape on the side of the microswitch to prevent it from coming off in future. When this switch is not made, it will not allow the ignition switch to turn to the off position from ACC and it will not allow it to release the key. However, if you do not feel comfortable performing the repair, there is a 'secret access hole' under the steering colum, it is a small square door you can pry off so that you can put your finger in to it an depress a small round button that will allow you to rotate the key to OFF and remove it. And yes, you pretty much need three arms and have to stand on your head to do this, but, it will allow you to turn off the ACC and remove the key.
SOURCE: Saturn Ion 3 Ignition Cylinder Lock
Im thinking your going to be ok as far as warranty repair,if your dealers service dept is insensitive, call Saturn assist @ 1.800.553.6000 On to the ignition switch ....separate colum halves with #2 screwdriver> access ignition housing and look for trip slot on top side of cylinder>use pocket size screwdriver to trip button in slot while in ACC position and pull out...good luck
SOURCE: 06 saturn ion has key
Make sure it's in Park (if automatic). If so, or if it is a manual, turn the steering wheel (even if it's locked in) and the key will release.
SOURCE: key stuck in ignition switch 2006 ION SATURN
either the lock cylinder came apart in the housing,which if it did you will need a new cylinder/key/housing and program the housing and build the lock cylinder(take to deal)or the ignition switch went bad (electrical part on end of lock cylinder) bith are common ion issue. i would take to the shop,they should have all those parts in stock
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