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Valerie,
You said all brakes wne tout. Did they do this all together, or did the fronts go out and the the backs? It does sound like the entire brake system is faulty. Has anyone checked out the ABS computer unit? It could be a computer problem as well.
Since volvo has come out and found nothing wrong with it, I would recommend the following:
1. Yes, I am a lawyerr and I do recommend you file a complaint under the lemon law of your state. Volvo's statement about war is a scare tactic. Call them on it. Under the lemon law, they will have to respond with what they have tried to do. Their discouragement is designed to force you to default by missing a key date. Don't worry. File your complaint and try to pursue the matter with volvo. This way you have preserved your rights and volvo knows you are serious. Don't back down.
2. Take your car to a brake specialist and have them issue an poinion as to the cause. sometimes a party involved in a dispute does not see things as clearly as a disinterested party. Also, take it to another volvo dealer who doesn't know you and tell them the problem. This item is under warranty. Sometimes another dealer will find something wrong.
3. File a letter of complaint with the feds. Also, find out form both the fed and your state how many other complaints of this nature were filed. If it's more than just you, there may be a design flaw.
4. Post another message here detailing specifically (yes get out all your paperwork and make your message long) what occurred, when, and in what order. List things such as how you drive, with one foot or two, who drives it, How you stop (you know, do you jam on the brakes or do you softly depress them causing your rotors to heat up because of the long time of contact between the pads and rotors.)
I understand your concern about brakes. On my 95 turbo, I took it in because of lots of squeaking. They looked at and it told me it just needed some oiling to reduce the noise. I still noticed a lot of grinding when I hit the pedal. I took it back. Another tech found that the rotors were being heated up by the pads and warping them. Both rotors and pads were replaced free of charge (just today) and the brakes feel a lot better.
Be persistent and let us know how things are going.
Delgado-Rucci
San Diego (formerly of New Jersey, so be nice to the Garden state)
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