2004 Ion Fan Speed Switch Going Bad
 

I already know the resistor is out, as it only works on 4 (highest setting), but a new problem has now developed.

When on 4, it started going in and out (bumping the switch made it work again). It slowly (over a few weeks) got worse and worse until now, I have to push in and twist the switch and hold it in order for the fan to work.

I really don't want to pay a dealer... Is this something I can fix myself? Has anyone else had this issue and fixed it?

Yes you can fix it yourself. You need to buy, and replace the control head, you can find them on ebay. The resister is under the dash and many times can be repaired, but it is just as easy to replace.

Okay, good to know. Thanks for the heads up.

So I see that I can indeed go this route 2003 2004 2005 2006 2007 Saturn ion A C Heat Climate Control | eBay

I'm wondering if I can simply replace the switch itself though. Seems like I shouldn't have to replace the whole head when only one component is out.

Maybe that's just how it goes though?

Maybe it's all cast as one piece. I don't know, just guessing, but I had the same thought as you.

That's what you need alright. The resister many, many times is a melted down contaction. Most times repairable by replacing the male connector after removing melted plastic. Another thing RjION showed me how to repair.