The buttons directing air flow to the windshield, front and lower vents did not function.  I pulled the unit several times to clean connections,  and try to clean the inside of the unit.  Immediately after cleaning and reinstalling the unit the buttons work fine.  Soon thereafter the buttons stopped working again. 

During the last reinstall I noted that if I pulled up on the connector for the buttons (top center wire connector) the unit functioned fine.  Evidently the wires pulling down on the connectors impacts button contact inside the unit.

My solution- wood shims!  The two shims are cut so they provide support to the connector, and rest on top of the frame for the cable controlling air temp.  See pics below.  The unit now almost operates flawlessly, the exception being the recirculate button does not light up.  

Should have included, car is a96 Legacy

The circuit board right in front of the connector develops opens in the circuits.  Putting the shims in closed the circuits, at least for now.