Sixth-seed Tsonga swept to a 7-5, 6-3, 6-3 triumph to reach his first semi-final in Paris and first by a home player since Gael Monfils in 2008.
The 28-year-old will tackle Spanish fourth seed David Ferrer for a place in Sunday's final.
Victory also helped wipe out the misery of his quarter-final in Paris last year where he had four match points over Novak Djokovic and lost in five sets.
"I never dreamt of this moment. Today was my moment against a champion who has won everything. "I didn't think I would get this far without losing a set. But Ferrer has not lost a set as well, he's in great form."
Federer, in his 36th consecutive Grand Slam quarter-final, was bidding to win a record 58th career match at Roland Garros and reach his 34th semi-final at a major.
The 17-time Grand Slam title winner also had the advantage of a 9-3 career lead over the French star, but Tsonga had been the man to beat Federer from two sets to love down in the Wimbledon quarter-finals in 2011.
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