The present investigation deals with the failure load prediction during the wrong procedure of unlocking the hand brake valve. The design of the hand brake valve top cover should have adequate strength such that the driver cannot move the lever without lifting the sleeve during brake off condition. The objective of this work is to design the top cover with higher strength such that it requires more load during wrong procedure of unlocking the valve. In this study, the nonlinear analysis is conducted (which includes three types of nonlinearities namely material, geometry and contact) in order to study the strength of the top cover during abuse condition. The design adequacy of the top cover is estimated by elasto plastic analysis. The maximum load carrying capacity of the top cover is determined from Force Vs Deformation plot which is good in agreement with the experimental results. Various design iterations are carried out to propose the appropriate design. The computer simulation of the nonlinear analysis significantly reduces the time and cost required to design the top cover according to the customer requirement.