Background: Locally recurrent papillary carcinoma of thyroid is a treatable disease. Tracheal infiltration is associated with impaired tumor free survival and increased disease specific mortality. Advanced surgical technique has now allowed tracheal reconstruction with extended tracheal resection at the same time preserving vocal cord function and increasing survival. Case presentation: A 46-year female patient with a history of total thyroidectomy + bilateral neck dissection for carcinoma thyroid two years back presented with recurrent thyroid mass in neck with endotracheal invasion. This was successfully treated with segmental tracheal resection with end-to-end anastomosis after 4 cm defect. Post – operative course was uneventful. Conclusion: Endotracheal invasion of recurrent carcinoma thyroid is not a contraindication for surgery. Full circumferential resection and end to end anastomosis is preferred to shaving trachea. It can be safely anastomosed up to 5 cm defect length. Apart from giving immediate relief of intratracheal bleeding and obstructive airways, it gives long-term disease-free survival.