Thoughts from my last visit...
The monorail’s problems are much bigger than poor maintenance. The general layout of the monorails were designed in the 1960s*. Since the 1960s, Americans have become fatter and utilize wheelchairs, scooters, and strollers to a greater degree. This results in reduced capacity. When one person is taking up the place of two, and one stroller is taking up the place of four, you see capacity decline measurably. To make matters worse, the monorails are not at level with the station platform. This means ramps have to be pulled out so wheelchairs and scooters can be accommodated. This drastically increases the amount of time it takes to load at each station. With new security checks at the hotels and general high attendance, we also can observe the station platforms overcrowding. The cars are too small for a modern mass transit system. Both height and width can leave guests constrained. All of this issues are solvable with modern mass transit solutions.
They need new trains, new stations, and probably new track to provide a world class experience. Improvements like larger stations, bigger cabins, and at level doors would drastically improve the customer experience. Other mass-transit systems are moving towards connected cabins. That means if one cabin is too crowded, guests can move through the train to another less crowded car. They also need to be running more than two monorails on the resort line. It should feel like a monorail is arriving constantly.
The amount of manpower it takes to operate a monorail at each station is crazy. Gates could open and close automatically, and it would also measurably improve monorail speed. I do understand Disney’s hesitancy to just leave the station open to the beam.
What would this cost? It would cost lots of money. Though some small company back in the late 1960s decided to do the same thing media conglomerate Disney can’t do now. Disney has no reason to be making its customers suffer in these unreliable and dated trains. Disney of the 1960s did its job, and it’s time for the Disney of the 2020s to follow up.
*The Mark VI was different, but still a derivative of Mark IV