" I have learned from these and other threads is that just about anything is at the dealer's discretion. "
Not when it comes to what is and is not covered by a Volvo new car warranty. All this info is in black and white in your paper work. If a dealer wants to give you what is called "good will" on a item that is out of warranty.....that IS up to them. Good will can be given for a few reasons.....like you use ONLY that dealer to repair your Volvo, or a item failed just after the warranty was over.

" I have read the warranty materials and it says that rotors aren't covered. However, what I have also read in several threads is that rotor wear is not covered but rotor warpage is. "
On this subject I THINK I would belive what it says in my Volvo warranty paper work, and NOT what a thread on a forum says. Warpage is a form of wear. I have heard of a few S/V40's getting rear rotor replacment for warped rotors that came from a problem that was known to have started at the factory.

" I have researched this on the BB and other forums."
If you have info yhay shows what I say here is not true....please post the link.

OH....and in 99% of the cases rotor life is not mesured in how many miles you get out of them(ie: all highway miles vs. all city miles....what one will wear out rotors faster?), but how many times you can replace the pads without NEEDING to replace the rotor.
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Steve F. in Hoboken, NJ