The Yorkshire side also knocked Liverpool out of the competition that season before falling to Cardiff City in the semi-finals.
So where are those players now?
The goalkeeper was man-of-the-match in his first game for the club in the previous round against Liverpool and that was the start of a brilliant relationship between club and player.
The former Manchester United player is still The Tyke’s number one stopper five years on.
Very popular among the fans he left Barnsley in 2009 to go and play in Qatar.
After a brief return to the English game with Doncaster Rovers he signed for his current club OFI Crete of Greece in 2011.
The centre back went on to become the team’s captain before being replaced in 2010 by Jason Shackell.
He remains at Oakwell.
The veteran defender returned to Sheffield United in 2010 before short stints at Port Vale and Bradford City followed.
He is now plying his trade in the Northern Premier League Premier Division for Ilkeston FC.
Marciano Bruma-Van Homoet
The brother of Chelsea starlet Jeffrey Bruma he returned to Holland in 2009 with Willem II.
A stint in Poland with Arka Gdynia and Lech Poznan followed but he is now back in his homeland with third division side Rijnsburgse Boys.
The stalwart is still at Barnsley and will enter his tenth season at the club next year.
The winger played a major role in both FA Cup fixtures assisting goals from Stephen Foster and Kay Odejayi.
After a stint with Tranmere Rovers and one game for Bohemians he signed for Kidderminster Harriers in February 2013 on a deal till the end of the season,
The Jamaican international is currently having an excellent debut season with Notts County in League One.
The captain who scored the winner against Liverpool went on to play for Sheffield United and Reading.
He was released by cash-strapped Portsmouth in January but found new employers in the form of Bristol City in February.
The Hungarian international left at the end of the season and embarked on a goal laden two season stint at Ferencvaros in his homeland.
The 35-year-old is now playing in the Hungarian second division with Gyirmot SE.
He scored the winning goal in the Chelsea tie and his performances for Barnsley that season earned him his one and only Nigeria cap.
After winning Player of the Season at Colchester United last year he is now having a stellar season at League Two outfit Rotherham United.
The Welsh international is now a team-mate of Odejayi’s at Rotherham.
Stints in Spain, Germany and Cyprus have led the 29-year-old to Kerkyra in Greece.
Currently on loan at Crystal Palace after a move to Norwich City last summer.
Now playing for York City in League Two after a successful spell at Grimsby Town.
Went on to captain Scunthorpe United before signing for Chesterfield Town at the start of the season.
Can Barnsley do to Manchester City what they did to Liverpool and Chelsea in 2008?