Update with award travel nearly complete.
Outbound in XN no upgrade until at -48 hrs I had my fare changed from XN to X then upgraded next sweep. My wife still in XN on a split PNR did not appear on the list, United Club agent tried to add her and said she got an invalid fare notice.
Return in X I was upgraded at -120 hrs. Wife also in X appears on the list at checkin. Currently 150 min prior to flight 5 in FC (all upgraded) +9 on the list with 20 available seats. At OCI offered $99 buy up (declined) was #1 of 5 on list. Now #3 and was offered $109 buy up when re-checking in at the airport.
The list is shorter than available seats so I assume she (and everyone on the list) will get upgraded sometime in the next hour or so.
Clearly XN is broken for upgraded.