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Has anyone inspected for a correlated problem other than the brakes? I experienced these same symptoms in my 740 a few years ago, and it turned out that I needed to replace a couple cheap suspension parts (strut rod bushings). This, and a switch to softer pads, got me from 11K per brake job to 45K.
Volvo OEM rotors and pads are fine, as the new pads are soft (and dusty). Wheels should be hand-torqued to 70 lb ft. But first, consider having your suspension inspected for parts wear that could be placing additional stress on your brakes.
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 David 1998 S70 T5SE // misc mods (mostly lighting) // red calipers 1992 940 GLE // Hella Micro DE foglights and 170K
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