Tire maintenance is a ubiquitous task in the automotive industry, and the limitations of traditional wheel spanners have long been recognized. To overcome these challenges and enhance the efficiency of tire bolt removal, a novel machine design has been developed and rigorously evaluated in this study. The design integrates a planetary gear system with a modular wheel spanner approach, allowing for adaptability and ease of use. Factors such as load distribution, tooth strength, contact stress and safety margins were meticulously considered to ensure optimal gear performance. Advanced machining techniques were employed, focusing on the design and analysis of the planetary gear train, particularly emphasizing the sun gear as the primary input member and the fabrication process, including turning, milling, boring and broaching. An electric motor, powered by the vehicle’s battery through the cigarette lighter port provides the necessary torque input. Performance evaluation was conducted to determine the efficiency and usability of the developed wheel spanner, utilizing rigorous mathematical calculations. The analysis revealed an exceptional overall efficiency of 97.62%, indicating minimal energy losses within the gearbox. Furthermore, the lightweight design weighing just 16 kg enhances maneuverability and facilitates easy handling during operation, contributing to its user-friendly nature. The proposed modular wheel spanner presents a significant advancement in tire maintenance technology, addressing the shortcomings of traditional tools. Its innovative design, incorporating a planetary gear system and modular flexibility, offers improved torque output and efficiency, reducing the effort and time required for tire bolt removal.