Monaco Windsor Driver Window Removal: Complete Weight, Safety, and Replacement Guide

Bottom Line Up Front

Your 2002 Monaco Windsor driver's side window weighs approximately 45-65 pounds depending on the exact configuration - consult Monaco specifications for your specific window model for precise weight, and yes, you absolutely need two people to safely remove it. The condensation buildup you're experiencing in the sliding portion typically indicates failed window seals or moisture infiltration between the dual panes. This is a common issue on Monaco coaches of this vintage, and while removal is straightforward, the weight and awkward dimensions make it a mandatory two-person job to prevent injury or glass damage.

Root Causes

The condensation building up in your Monaco Windsor's sliding window is almost certainly due to seal failure between the dual-pane glass assembly. Over 20+ years, the primary seal (typically butyl rubber) and secondary seal (usually silicone or polysulfide) deteriorate from UV exposure, temperature cycling, and general aging. When these seals fail, moisture-laden air infiltrates between the glass panes.

Monaco used Hehr or similar OEM windows on the 2002 Windsor models, and these units commonly develop seal failures around the 15-20 year mark. The inert gas between the panes escapes, allowing humid air to enter and condense when temperature differentials occur. Unfortunately, once this happens, the only permanent solution is either professional reglazing of the window unit or complete replacement of the glass assembly.

Road vibration and chassis flexing in motorhomes accelerates seal deterioration compared to residential windows. Your Monaco's air ride suspension helps, but two decades of highway miles still takes its toll on window seals. The sliding mechanism itself may also have worn weather stripping that allows additional moisture infiltration.

Before You Start

Gather your tools and materials before beginning: you'll need a cordless drill with Phillips and flathead bits, a putty knife or trim removal tool, work gloves, safety glasses, and most importantly, a second person to help. Clear a large, soft area near your RV where you can safely lay the window assembly - old blankets or moving pads work well. Check the weather forecast and choose a dry day, as you'll have an open window cavity for 30-60 minutes.

If your window has any electrical connections (uncommon on driver windows), disconnect your RV's battery to avoid electrical issues. Take photos of the window assembly from multiple angles before starting removal - this documentation will be invaluable during reinstallation. Examine the exterior trim and caulking to understand the removal sequence. Monaco typically used a combination of screws and sealant to secure these windows.

Prepare for the weight by positioning your helper on the exterior side of the RV. The window assembly is not just heavy but also awkward to grip, with most of the weight concentrated in the glass portion. Plan your grip points in advance and establish clear communication signals with your partner. Have a clean, safe storage area prepared where the window can rest without risk of damage.

The Repair Process

Start by removing the interior window trim and hardware. Your Monaco Windsor likely has plastic trim pieces secured with Phillips screws around the window perimeter. Remove these carefully and set the screws aside in a labeled container. Behind the trim, you'll find the main mounting screws that secure the window frame to the RV's sidewall structure.

From the exterior, carefully remove the butyl tape and sealant around the window perimeter using a putty knife. Monaco used generous amounts of Sikaflex or similar sealant, so this step takes patience. Work slowly to avoid gouging the RV's sidewall. Once the sealant is cleared, locate and remove the exterior mounting screws - typically 8-12 screws around the window frame.

With all fasteners removed, have your helper work from inside to push the window out while you support and guide it from the exterior. The window will want to fall outward due to its weight and the typical installation angle. Lift straight out and away from the opening, keeping the assembly level. Move deliberately to your prepared storage area and inspect the window opening for any damage or deterioration that needs attention before reinstallation.

For the condensation issue, you have several options: contact a local glass shop for resealing quotes (typically $150-300), order a replacement window assembly from Monaco/REV Group parts (expect $800-1200), or install temporary desiccant packets inside the failed unit as a stopgap measure while you explore permanent solutions.

Professional Help Needed

While window removal is within most DIY capabilities, repairing the condensation issue professionally is often the most cost-effective approach. Local glass shops experienced with RV windows can reseal your unit for significantly less than replacement cost. They have the proper equipment, sealants, and expertise to restore the window to like-new condition.

Consider professional help if you discover structural issues around the window opening during removal, such as delamination or water damage to the sidewall. Monaco Windsor coaches of this vintage can develop moisture infiltration problems that extend beyond just window seals. A qualified RV technician can assess and address any underlying issues.

Installation of the repaired or replacement window also benefits from professional expertise, particularly ensuring proper sealant application and weatherproofing. Poor installation can lead to water leaks that cause expensive structural damage. Many RV service centers offer window installation for $200-400 in labor, which is often worthwhile for peace of mind on a coach of this value.