Ex-Reds Craig Davies and David Perkins both missed penalties as Barnsley won at Wigan Athletic in a shoot-out to reach the area final of the Johnstone's Paint Trophy.
Adam Hammill put the Reds ahead just before the break but Wigan levelled early in the second half. Ivan Toney headed Barnsley back in front five minutes later with his first goal for the club then Wigan levelled late on to force the shoot-out.
The Reds won it 4-2 with successful kicks from Conor Hourihane, Toney, Sam Winnall and Alfie Mawson.
Head coach Lee Johnson made just one change to the side that drew with Sheffield United a week earlier with Ivan Toney coming in for the benched Lloyd Isgrove and Marley Watkins moving onto the right wing.
Although they survived an early penalty shout for a possible foul by Hammill, the Reds were the better side in the first half.Toney headed just wide from a cross by Hammill who then embarked on a 40-yard run before his shot was tipped over by Jussi Jaaskelainen.
Hammill eventually gave Barnsley the lead on 42 minutes when he cut in from the left, beat a defender and curled into the bottom right corner from the edge of the box.
Wigan brought on Yanic Wildschut at the break and his cross was turned in by Will Grigg via a deflection from Nyatanga three minutes into the second half.
But Barnsley were soon back ahead when Toney headed in from close range after Jasskelainen had saved a Hourihane shot.
The Reds nearly scored another own goal as Alfie Mawson's sliced clearance was brilliantly touched onto the bar by Adam Davies. Wigan's Jason Pearce then blasted back across goal when he looked certain to score one yard out from a corner.
At the other end, Nyatanga almost made it 3-1 when he lifted over from close range after Marley Watkins headed down a cross.
The hosts levelled in the 82nd minute when Will Grigg turned in a right-wing cross by ex-Red Craig Davies so the match went to penalties.
After Max Power and Hourihane scored their penalties, Davies blazed his over the bar. Toney netted then Adam Davies saved from Perkins. Winnall and Jordan Flores netted before Mawson won it. Barnsley will play either Morecambe or Fleetwood in the Northern final with the winners going through to the Wembley final.
