I had a similar problem before I was aware of this thread. My Ion is one of the original 50 preorders and I've been extremely pleased with the light since I received it. It didn't see a great deal of use because it was still thicker than what I wanted to carry in my pocket, so my ARC AAA remained my EDC.
Being in the 50+ crowd, my eyes require more light than they used to for just about everything in low light conditions, and it's gotten worse in the last year. For the last several months the CR2 Ion has been on a lanyard around my neck in the car and at home whenever it's dark, even in bed while sleeping.
It recently developed problems very much like Frank described. Flickering, skipping low, etc. I cleaned the threads like I do with the ARC, but that didn't take care of the problem. I tried a new Duracell even though the BS cell in it was not shot (I changed from the BS cell only because the new Duracell was handy - I didn't know there were any problems with the BS cells), but that still didn't resolve the problem.
I emailed Enrique and got a phone call from him the following day. He suggested the retaining ring fix that greenLED referred to. We had a very pleasant conversation and he sincerely apologized several times for my inconvenience. I didn't feel that he owed me any apology and told him so. If the fix didn't work, I was to email or call back and we'd do whatever was necessary to resolve it.
I tried the "fix" when I got home, and while it was better, it still didn't resolve all of the issues. I decided to clean the two contacts with Deoxit, even though they looked perfectly clean. I couldn't believe how dirty the negative contact was after applying the Deoxit although I still think that the problem was the positive switch. My guess is that the switch was dirty, oxidized, and "sticking" and the Deoxit did the cure.
The light is now noticeably brighter and works flawlessly. The on / off points are again perfectly consistent. I now know that my Ion will require periodic cleaning like my ARC does. No biggie, in fact, shame on me for not thinking that it would.
I couldn't ask for better customer service and a sincerely concerned attitude from Enrique - not surprised, after all, it is a nearly perfect light.
Shameless plug for Deoxit - if you don't have it - get it. The stuff is miraculous!