Description

Challenger MT800, MT635, MT845, MT855, MT865 2005 Parts Catalog

You need a part for a Challenger MT800 series tractor. You pull the old one off, measure it, and start hunting online. Three hours later you are looking at a box with a part that sort of fits but the bolt holes don’t line up. That is time and money down the drain. That is exactly why this 2005 OEM Challenger MT800, MT635, MT845, MT855, MT865 2005 Parts Catalog exists – to kill guesswork with factory part numbers and exploded views. No aftermarket cross-reference. No “this should work” nonsense. Just the part numbers and illustrations the factory used to build these machines.

Every parts catalog from the dealer costs you an hour of billable time just to get someone on the phone. This 1265‑page document puts every assembly – from the air cleaner GP to the brake AR – right on your screen. Print what you need, keep the rest digital. I have been turning wrenches for 28 years and I can tell you: the moment you stop relying on aftermarket part lists and use factory documentation, your parts ordering error rate drops to near zero.

What This Parts Catalog Actually Covers

This is the official Challenger parts manual for the MT800 series track tractors produced in 2005. It covers the MT635 (serial BAM40001‑59999), MT645 (BBP40001‑59999 – note: the manual also lists MT845 which is the same designation), MT855 (BCC40001‑59999), and MT865 (BDS40001‑59999). It also includes transmission 9YF1‑Up and axles AZG1‑Up, AZH1‑Up, AZJ1‑Up, AZK1‑Up. The document is organized by major systems: Machine Arrangement, Engine Installation, Cooling System, Air Inlet and Exhaust, Fuel System, Electrical and Starting System, and more. Each section breaks down to specific assembly groups with part numbers, quantities, and illustration references. Page 3 gives you the alphabetical index – use it to find any major group fast. Page 4 shows a sample of the numerical index and the start of the air inlet and exhaust section, including the AIR CLEANER AS‑BASIC for MT835/845 (part 192‑8980) and for MT855/865 (196‑4056). That level of detail runs all 1265 pages.

Engine Installation Arrangement and Cooling System: Where the Part Numbers Matter

Need the alternator mounting group for an MT865? The manual lists MOUNTING GP‑ALTERNATOR (206‑6987) as a separate assembly with its own bolt and bracket numbers. The COOLING SYSTEM section gives you the fan guard part for the MT845 (228‑4631) versus the MT855 (228‑4632) – they are different. If you order the wrong guard, you are not bolting that radiator core in place. The manual’s exploded view shows each fastener, and the text indent tells you whether a bolt is included with the assembly or ordered separately. That kind of specificity is what keeps a job from turning into a parts run. Aftermarket catalogs lump everything under “fan guard assembly” and you end up modifying brackets. This manual gives you the exact part number, period.

3 Ways to Avoid Ordering the Wrong Part

First: use the alphabetical index on page 3 of the manual. It lists every major assembly name and the page where the illustration appears. Second: cross‑reference the numerical index if you have an old part number from a previous repair. The numerical index tells you which page and grid location that number appears on. Third: always check the “hardware not included” notes. Common hardware like bolts and lockwashers are indented under the item they attach to – if you need them separately, the indent tells you they are not included. That saves a trip to the dealer.

Alphabetical and Numerical Index: How to Navigate 1265 Pages

The manual starts with a forward on page 1, then jumps into the alphabetical index on page 3. The numerical index runs immediately after. If you are looking for “AIR COMPRESSOR GP” for an MT855, you go to the alphabetical index, find that name, and see the page number. The illustrations are always on the left‑hand page, parts list on the right. Each part gets an item number that matches the illustration callout. This is standard OEM documentation – no guessing where a bolt goes because the picture shows it. For contrast, grab any aftermarket parts catalog from the web and try to find the “LINES GP‑TURBOCHARGER” (503583D1) for an MT845. You will be scrolling through 50 pages of generic turbo line sets. Here, it is one entry in the Engine Installation section with a clear illustration.

Why OEM Documentation Beats Aftermarket Cross‑Reference Lists

I have seen aftermarket catalogs list a fuel tank part number that crosses to the wrong variant of the MT800 series. The FAN GP (206‑6397) on the MT865 is not the same part as on the MT635. The OEM manual gives you the exact part number per serial number range. The Automotive Industry Overview might teach you general manufacturing, but it won’t tell you that the BRAKE AR (185‑8860) for the air trailer is different from the brake kit on a standard MT845. This manual includes that distinction. For a broader look at agricultural machinery, see the Automotive Industry Overview – but for day‑to‑day parts ordering, stick to the factory print.

Don’t trust a third‑party scan that might be missing pages. This is a direct OEM PDF from the 2005 release, with all 1265 pages intact. The file name itself references the braking system section, which is included in this catalog. Every assembly group – from BASIC UNIT AR‑MT835 (156‑5581) to BASE COMMON AR (179‑1952) – is searchable.

Frequently Asked Questions

Does this manual include part numbers for the MT635?

Yes. The MT635 is listed under serial number range BAM40001‑59999. The Engine Installation section includes MOUNTING GP‑ENGINE (172‑5333) specifically for the MT635.

Can I use this to find the alternator mounting parts for an MT845?

No. The manual covers up to 2005 model year. The MT800B series uses different part numbers for the fan drive and mounting groups. You need the Challenger MT800B Series Tractors Parts Manual for that. For earlier CVT models, see the Challenger MT 655B 665B TECHstar CVT Parts) and for the 700B series, check the Challenger MT700B Series Track Tractors Parts Manual.

Stop ordering parts blind. Access the Factory Manual and keep it on your shop tablet or printed binder. One correct part number pays for the whole catalog.