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Drive Unit failure symptoms and thresholds for replacement

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Here's another way to look at it.

With an entirely new design, there are always going to be a lot of problems. Many will be fixed quickly. Some will take much longer to diagnose. A few will take a really long time to diagnose.

Numerous issues (such as the mirrors corroding, or the galvanic corrosion design mistake in the frunk area, or the massive noise caused by the A/C compressor rubbing against other parts) were fixed within the first year.
The 12v battery failed due to three separate problems: (1) a poor specification for the batteries, (2) a bad batch of batteries, (3) the system putting a bad load profile on the batteries; all three have been fixed now (though people still occassionally get dud batteries).
The electrical-contactor arcing buzz in the battery pack was diagnosed relatively soon after that and fixed.
The "highway hum" took a long time to diagnose but finally appears to have been fixed.
The "clunk" may or may not have been diagnosed yet.
The "milling" at lower speeds has not been fixed yet.

It worries us because the remaining undiagnosed problems are potentially quite serious. But they have been identifiying and eliminating design flaws sequentially, and as long as they keep engineers working on this, they'll probably get them all fixed before the extended warranty period is out.
 
Had an S60 while our front du was being replaced and I was impressed that it was completely silent. The 60 was much more enjoyable to drive than the 70D, due to the complete lack of motor noise. Ours is now back, and although the replacement DU is quieter, it is far from silent.
 
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