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Probably because the replacement units are no different from the original units .
From Volvo's perspective, they have lived up to their end of the bargain. They have provided you with a functional A/C system through the life of the warranty. And where those units have failed during warranty, they've replaced those units at their expense. I realise that you are not satisfied with that, but I am just speaking from their perspective.
Now, since they feel they have satisfied their obligation, they don't see a need to fix something that, in their thinking, isn't broken.
To correct a problem with something as complex as a A/C evaporator, would take hundreds of thousands of dollars, if not a million or more. As far as they are concerned, why spend money on retooling for an obsolete car, especially if the owner is going to be paying for it anyway. I assume that the warranty for the replacement part is relatively short, so no skin off of their backs. In fact, it is a profit center for them.
In my opinion, bottom line, if you feel Volvo has not lived up to it's end of the bargain, your next purchase should be other than a Volvo--and that is the best, and most direct, message you can send to Volvo. Yeah, you can sue them, but speaking from experience, the lawyers will get rich, and you will lose a few years from your life. The reason you have gotten minimal response from the lawyers is that they are evaluating your case on a very detached basis. You may think you are on the white horse. But lawyers rarely care about white-horse causes. They are looking for a payout. And as much money as you think Volvo has, the lawyers see a lawsuit suit with distinctly defined damages--something that can't be stretched into hunreds of millions of dollars.
I can tell you, in my case, my next purchase will not be a Volvo. Not because of this A/C problem, but because of general quality control issues and reliability concerns. As I have mentioned in other postings, I've owned Japanese cars--Hondas/Acuras--very, very very reliable cars. So, I've been to the mountain-top and looked into the promised land. And the promised land doesn't have Swedish cars in it.
My next car is a BMX Mini Cooper S.
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