Manager Simon Davey was quite prolific in the summer transfer window, bringing in no less than fourteen new players and spending around £1 million, the majority of this on three strikers.
Strikers: Kayode Odejayi (Cheltenham), Miguel Mostto (Cienciano), Kim Christensen (Odense Boldklub) Midfield: Anderson Silva de Franca (On loan from Everton), Jamal Campbell-Ryce (Southend United), Dominik Werling (Sakaryaspor), Andy Johnson (Leicester City), Rohan Ricketts (Wolverhampton Wanderers) Defenders: Rob Kozluk (Sheffield United), Dennis Souza (RAEC Mons), Lewin Nyatanga (on loan from Derby), Stephen Foster (Burnley), Marciano Bruma (Sparta Rotterdam) Goalkeeper: Heinz Muller (Lillestrøm S.K.)
The most successful of these signings included goalkeeper Heinz Muller, midfielders Anderson and Jamal Campbell-Ryce, and a new defensive line-up made up of Rob Kozluk, Dennis Souza, Stephen Foster and Lewin Nyatanga (who returned on an extended loan spell after becoming a fan favourite).
Barnsley had a very positive start to the season, surpassing expectations and finding themselves in the top six of the Football League Championship with ten games played.
Top scorer Brian Howard was rumored to have attracted Premiership interest along with new signings Heinz Muller, Dennis Souza and even manager Simon Davey.
After conceding a goal in the first half, it was Stephen Foster who equalised in the second and captain Brian Howard who scored the last-gasp winner which allowed them to progress to the quarter finals for the first time since 1999, where they would face Chelsea at Oakwell.
Even Chelsea boss Avram Grant admitted after the game that the Championship side fully deserved their win Davey hails giantkillers Barnsley.
With Portsmouth the only Premiership side remaining in the competition, what had begun as a shock result at Anfield had now developed into a genuine chance to reclaim their FA Cup glory, and when they were drawn against Cardiff City in the semi-finals a repeat of the historic final versus West Bromwich Albion was well on the cards.
Meanwhile, in the league, losses against Crystal Palace, Sheffield United and Burnley saw them drop to a precarious position and relegation fears were brewing, but a surprise 3–0 away win at Watford followed by a 1–2 victory at Preston North End were a big boost to their survival hopes.
In the second half, goals from Kevin Kyle, Julian Gray and Michael Mifsud tied up an easy win for the sky blues.
After a dull first half, Reds substitute Istvan Ferenczi, who replaced Miguel Mostto scored with his first touch, a header from Rob Kozluk's cross.
Former Tyke Tommy Wright then levelled for Darlington before Reds skipper Paul Reid rifled a bouncing ball into the net to seal Barnsley's passage to the next round.
Filipe Teixeira lashed Albion in front after thirty minutes and Craig Beattie benefited from poor defending and beat Heinz Muller with ease.
However Barnsley fought back, and in injury time substitute Kim Christensen scored his first goal for the club to earn a dramatic away point.
Match Twelve – Hull City 3–0 Barnsley A debacle of a performance saw Fraizer Campbell bag a brace and Dean Marney score late on condemn the Reds to their first defeat in seven games.
The away side had a huge chance to equalize in the dying seconds of the game when they were awarded a penalty, but keeper Heinz Muller made a stunning save to tip it round the post and maintain his clean sheet.
Istvan Ferenczi widened the gap in the second half with another goal from a header, but Blackpool pulled one back minutes later thanks to Keith Southern.
Hungarian forward Istvan Ferenczi was denied his third goal in as many games when his header was controversially ruled out by female assistant Amy Rayner.
Two goals in quick succession from Brian Howard and Martin Devaney look like giving Barnsley a 2 – 0 lead going into half time but two headers from Watford defender Danny Shittu made things all square going into the break.
Match Eighteen – Sheffield Wednesday 1–0 Barnsley The South Yorkshire derby was settled on the hour mark by a header from Akpo Sodje.
Istvan Ferenczi scored the only goal of the game just after half time, and minutes later goalkeeper Heinz Muller made a spectacular penalty save at the other end.
Brian Howard also found the net but said penalties and a well worked set piece gave Liam Lawrence a hat-trick to save Stoke.
Andy Crosby handled Miguel Mostto's shot in the dying seconds and Brian Howard netted in the seventh minute of added time.
The second half was evenly matched but in the last twenty minutes the hosts ran riot with Julian Gray, Jay Tabb and Best all scoring.
Down to ten men, Barnsley managed to hold off the home side until the final 15 minutes, when Plymouth débutante Jamie Mackie scored twice to make the win decisive.
Dirk Kuyt opened the scoring in the first half, but Stephen Foster headed in the equaliser in the second while loaned goalkeeper Luke Steele made several saves to keep Barnsley in the game.
Match Thirty-Four – Barnsley 0–0 Queens Park Rangers A poor game played out in shocking conditions ended 0–0 between the Reds and QPR.
The home side eventually exploited the gaps left open at the back when Martin Devaney delivered a perfect ball into the area for Kayode Odejayi to nod it into the net and score his first goal since September.
Early in the second half, Jon Macken headed the ball in from a corner to put Barnsley in front and then with 10 minutes remaining there was drama as Jamal Campbell-Ryce was brought down in the area and a penalty given, which Brian Howard scored for his 12th league goal of the season.
A free kick from January signing Diego León followed by a foul on Jamal Campbell-Ryce inside the area which led to a Jon Macken penalty secured this win, regardless of a Stephen Foster own goal at the other end.