Solved the issue. It looks like the Air Conditioner turns off by default even when you have it turned on when you stop the car. You must manually, turn the AC on each time you start the car.

 

I cant remember the exact sections of the infotainment system, but there is a setting in there to automatically control the ac. I turned that off and the ac stays on until I turn it off myself.

 

What really confuses me is that the manual points to a windshield fog detector that is supposed to turn on the A/C and defogger when using AUTO mode. However, my wife and I got in the car one evening after dinner with AUTO mode turned on and the entire inside fogged up in the time it took us to put on our seatbelts. We had to sit in the parking lot until the car warmed up ( it was only 25F and clear out ), and the defrost finally cleared the windshield so we could drive. I have learned to leave the car in Manual Mode with Defrost and Floor airflow. Then I have to manually turn on the AC mode upon starting. I will bring this up with the dealer at the 5K service.

 

Something is not right with your climate control.
AC is defaulted to ON every time vents are directed at windows. Also, there should be additional Windshield defog button. Both should automatically engage AC. Period. It's been like this for LONG time, lawyers made sure to have that that way.

 

Agreed. I'm at 4,400 miles and will be sure to mention this at my visit to the dealer...

 

Dropped the car off today to see if the dealer can find out why this car is always fogged up. Turns out the fresh air door assembly has a stripped gear and so the car is basically always in recirculation mode. They are keeping the car for 5 days to complete the repair. The service writer stated that he had just seen this with another customer and his Highlander. After I get it back and see what all was replaced I will post an update. Hoping that the repair doesn't result in a rattle prone dashboard after this repair.

 

Five days??

 

That's what I said. They are ordering a new actuator motor first because they aren't sure if the gear is included with the motor! If that doesn't work they will order a whole module.

 

Any word? Sounds like I have the exact same issue!

 

Well..... Dealer called yesterday to say the part they ordered wasn't correct. I asked if it would be done by 1/11 and was told he hopes so. Sounds like they got a bad batch of recirculation door servo assemblies. This might take a while to correct. Make sure they give you a loaner car!

 

Back from vacation. Problem fixed!

 

YEY!
Good to know. Thank you for sharing

 

 

DEFROST PROBLEM SOLVED 2020 Highlander,
Thank you for these post. I purchased this vehicle for safety and reliability for my family. This window fogging is very dangerous. I brought it to the dealership and they tested it and told me everything was fine and that I need to turn up the heat and direct the vents at the windows. They even told me that a water bottle in the car could be the problem LOL. I have owned several cars without a problem like this. This problem must be rare to be given advice like this from a Toyota dealership. I am certain this will be a recall. I reviewed a picture of a Toyota repair ticket in a previous post. I carefully removed the glove compartment and the cabin filter and could see two white pieces inside the there. I started the car and changed the switches back and forth from outside air, recirculate and defrost and nothing was moving. I reached in there and the white parts moved very freely. I moved them both inward towards each other. Again I want to say they moved very freely with zero tension. In my case they must be completely disconnected or something. I would not move them if there is any friction at all. I took the car for a test drive and it was perfect. Family is safe 👍 I will be calling the dealership again to have it repaired.

 

Glad that you figured this out. Your dealer should be able to figure it out now that you can tell him what is wrong!

 

Yes it was repaired by replacing the servo and gear that controls the recirculation mode door.

 

I'm spending my third hellish winter with Highlander in 2020. Is there a problem with my settings? Is the car the problem?

 

@Ben Heo As you can see already in this thread, some people had problems with the actuator for the recirculation function. That could lead to problems with defogging the windshield.

You should be able to hear the effect of the airflow changing when the button is pressed - do you?