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A lot of us came to 9-5's from 9000's, welcome!
bear in mind that the diags are not foolproof, but it sounds like the diags and your own testing confirm this is a "defroster issue".
I believe that defroster control linkage and motor are on the passenger side. you will want to take out the glove box, and peel back the carpeting on passenger side transmission hump. with it all exposed, run the diags again and watch carefully. You will see the linkages move, and likey see one that does not ... that is your culprit.
Once you find the culprit it can be a few things that I have seen in similar vintage cars:
- linkage popped out of its arm - rx: just press it back together.
- stepper motor jumped its gears - rx: put the motor in a vise and gently squeeze the shaft back into its case.
- stop arm broken - rx: replace the stop arm
- the "gear reduction drive" has stripped or broken gears. most of the stepper motors drive the arms and linkages through a reduction unit. the stepper motor is robust and made of metal. but the reduction unit is cheap-ish and made of plastic gears. these are pricey, but I have been lucky to find used ones still intact. rx: replace with new or used, or the use components from one to rebuild the other. Get used from goldwing, local junk yard or auction site.
- there are probably other failure modes as well ... but I have see the above *a lot*
The fact that you notice the air flow change seemingly at random, suggest it is simply a loose or unattached linkage.
The ACC box is really a simple and quite interesting system of mechanisms. getting access and watching it while you run the diags will take a lot of the mystery out of it.
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'08 9⁵ 2.3T SportCombi, Polar White
'01 9⁵ Aero Midnight Blue (benched)
'00 9⁵ Aero Midnight Blue (rescued)
'99 9⁵ Base model, Cosmic blue
'00 9⁵ Aero Silver (RIP - transmission )
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