A 65-year-old female presented with right upper quadrant pain and vomiting for 5 days. Imaging showed CBD stones. During a difficult ERCP involving pre-cut sphincterotomy, the patient developed tension pneumothorax. Exploration found a duodenal tear that was repaired. Tension pneumothorax is a rare but serious complication of ERCP due to retroperitoneal or intraperitoneal air dissection through diaphragmatic pores. Immediate diagnosis and treatment is needed to prevent hemodynamic compromise.