The conceptual designs for the manual tyre-changer machine (MTCM) was generated, detail design of the MTCM as well as proper material selection for the MTCM was carried out, and ultimately, the performance of the designed and fabricated MTCM was modeled and simulated. The results from the analysis showed that the design of improved manual tyre changer machine has mechanical advantage of bead breaker arm of 8.67, wall thickness of bead breaker arm of 4.8738mm, allowable bending stress of 80 N/mm2, allowable shear stress 40 N/mm2, shank diameter of bolt at A 10.84949mm, shank diameter of bolt at B 11.3743mm, height/thickness of nut at A and B 9.6mm, length of a side of the outer square section of insertion/extraction arm based on bending stress is 46.296mm, length of a side of the inner square section of mount/demount arm based on bending stress 38.58mm, angle of twist of a 60mm × 60mm × 5mm insertion/extraction arm while inserting/extracting a tyre on 16” × 7” rim was selected due to its lower angle of twist of 3.6848×10-9 rad. The circular pitch for the pinion gear was determined as 9.426mm.The circular pitch for the driven gear is determined as 6.284mm.The module for the pinion gear was determined as 3mm.The module for the driven gear was determined as 2.4mm.The number of teeth for pinion gear is determined as 20.The number of teeth for driven gear was determined as 30. The torque on driven gear is 4340.02N-mm and the force acting on gear teeth was determined as 144. 67N. The contact stress for the pinion gear was determined as 4.00N/m2. The ANSYS simulation results also showed that the maximum value of equivalent stress for the MTCM roller bearing was 3.2406Pa, the maximum value of equivalent elastic strain for the MTCM roller bearing was 7.8388 x 10-10m/m and the maximum value of total deformation for the MTCM roller bearing was 5.7215 x 10-8m. Conclusion and recommendations were made that ANSYS simulation tool applied in this study have shown that it is possible to predict how the machine components will behave in a real case and allows the engineer to see where the stresses, strains and total deformations will be the greatest and how the machine will behave with such occurrence to provide better reference for redesign of the machine.