It has the most frustrating control logic ever. In Colorado we have great cool, dry, clean air most of the time, and I want to breathe that not the stale air in the car. It recirculates when I want fresh air most, like if the car is hot and has been sitting in the sun, or if I turn the temperature colder because I don't want any heat on a cool morning. Most of the time it only turns itself on at startup, but sometimes while driving it decides that the outside air is too fresh, so it must suddenly make it hot and stuffy inside. Sometimes it goes on when I have the windows down. It's by far the stupidest feature of this vehicle, and possibly the only thing I don't like about it.
You could disable the recirculate actuator, but it's a pain to get to, and I don't know how you would disable it.
My plan is to make a circuit that connects to the LED and the switch. Whenever it sees the LED come on (detects the voltage), it will press the switch (electronically not mechanically) to turn it off. It would be easier to connect to the wiring that goes to the actuator, except that I don't think it's accessible. The thread that shows how to replace it doesn't show any kind of cable or harness, so it must be attached to where the actuator mounts. Maybe there's an output from the HVAC control panel that I could interrupt?
I am also planning on adding a switch to override the A/C compressor so it doesn't have to run when I run the defroster. I think the relay is called something like MAG CLT (magnetic clutch).
Maybe we just need a few people to crash as a result of the recirc and Toyota will have to do a recall to fix it.