I don't buy this argument at all. Why would VW spend another Reichspfennig on re-engineering the cam follower on an old motor that isn't getting any more development???
The followers and cams were failing while the FSI was still in production, several million were produced and with a 120k extended warranty thousands more are guaranteed to fail under warranty so I don't think developing and putting out a TSB for installing thicker/polished surface cam followers would be more costly than repairs...if that was a viable fix. For cars that had this repair done at 60k miles they is a good chance VW will be repairing many cars twice. Lets not forget in order for VW to release a TSI in 08' that addressed the issue they new this would plaque CURRENT FSIs probably since 2005 yet kept producing them for 3 more years so its unethical for them not to work on a solution.
How much money do you think John has to develop a cam follower? Whatever it is its chicken feed to VW. We are not talking about reinventing the wheel. On STOCK cars the cam followers generally lasted at least 60k miles. So if all it took was a cam follower revision that required thicker material (KMD did this long ago) and a polished surface to make them last 3 times as long why didn't VW just do that when it revised the cam follower. They already did a revision and I'm sure thickness and contact surface had to come up.
My guess is the thickness is making up most of the longevity here (KMD has a follower based on this concept). Can't convince me VW didn't explore a polished surface vs coating the contact surface. Cant convince me after the failures no engineers at VW didn't propose to just make future followers thicker so they last longer. There has to be a reason this wasn't done.