Beaten in a Finals Series thriller last season, Roar returned the favour by winning 6-5 on penalties after it was 1-1 at full-time.
Western Sydney dominated a frenetic opening period and took a deserved lead on the stroke of half-time when Terry Antonis converted from the spot.
Roar regrouped at the break and quickly levelled through joint Golden Boot winner Jamie Maclaren, before ratcheting up the pressure late in regulation time.
Vedran Janjetovic sent the match beyond 90 minutes by first tipping Corey Brown’s shot around the post and then somehow pushing a late Borrello volley onto the crossbar.
Brisbane gained the advantage when Wanderers substitute Josh Sotirio was shown a second yellow for going in late on Brown, leaving his side to see out over 15 minutes with 10 men.
They survived, but only until substitute goalkeeper Jamie Young batted away Jumpei’s penalty to seal’s Brisbane’s progression to a Semi Final date with Melbourne Victory.
0-1 Wanderers: Antonis (p), 45’+1’
After Papadopoulos tripped Santalab in the area, Antonis stepped up and struck his penalty enough power to Theo’s right.
1-1 Roar: Maclaren, 55’
Broich released Borrello in behind and, after the winger’s measured finish came back off the post, Maclaren was on hand to tap into an empty net.
Borrello (x), Antonis (x), D’Agostino (x), Dimas (x), Maclaren (x), Martinez (x), DeVere (x), Hamill (x) Kristensen (x), Cornthwaite (x), Oar (x), Jumpei (-)
Having entered the match as a substitute in the 87th minute, Josh Sotirio picked up two yellow cards either side of regulation full-time to leave his side with 10 men.
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