Thought I would post an update to this. Another year, another 6k miles and it is exactly the same, no better no worse so I am now of the mind that it is by design, abet a little bit more then it probably should be.
I have noticed that if I enable cruise, even at 30 mph it goes away which has convinced me this is a software 'feature'. For now it will be getting another gearbox fluid change this week as part of its regular service and it will continue to be my daily driver.
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Current Volvo's: S40 1.8 (55) & V50 2.4i (04)
Past Volvo: S40 1.8 ('97/R) & 240 GLE ('76/R)
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