My 2005 Saturn ION had trouble turning the key to start. The original key was bent and broken some time ago, so I do NOT have the key code sequence to correctly identify the factory one. The two spare keys created in the store were slightly different. One worked a little better than the other. Over time, none of them worked very well. When creating a new ignition code, there are 7 possible slots in a cylinder. I was able to determine which slots were the same between the two keys and left blank the slots with differences - no padding with a letter (lacking a better term). It worked great! I was able to create an ignition cylinder with the properties of two keys, where the gaskets and slots are almost the same. Yes, some code slots are not used. In my mind this is normal. A thief would still have to understand others correctly. Take the time to slowly go through possible pad combinations and take notes. All you need is a pair of pointed tweezers and a small screwdriver to set the pad sizes. Once the spacer is in place, you can pull it out and adjust it to a different size if it doesn't fit. You will not be blocked on your first attempt to code it correctly. If you already have a key code, it will make things easier.
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