After replacing the ignition switch and attempting the pass-lock relearn I finally got the car to crank, it cranked and cranked and cranked but would never fire. After I released the key to stop the cranking starter it gave me the pass-lock error on next attempt to start. I tried starting 10mins later and hit pass-lock all over again. Would cycle between pass-lock/cranking but no fire/pass-lock for the next 3 cycles in a row aka over the next hour.
I've got plenty of gas in the tank and had fired up fine (after the 10min pass-lock problem in the morning) that day.
More details if necessary are below:
I'd been having trouble with cold morning starts (below 45 degrees F) so I bought and replaced the ignition switch. I'd seen several write ups but used this one due to pictures and detail explanations.
MoonTaj Electronics - Saturn Ion Passlock Fix
I followed the steps up until they start trying to repair the old one, I used a new AC Delco part.
I tried doing the pass-lock relearn with turn key set off pass-lock leave in run position come back 10 mins later turn to off for 5 secs and repeat 3 times. It took 4 but it finally tried to crank as described in first paragraph.
I'm going back over to where the car is located after I finish this post and am going to try some more then possibly re-install old switch and see if it starts with it.
Any suggestions will be greatly appreciated.