Sunderland lost out 5-4 on penalties last night after Darren Powell's 90th-minute header gave Crystal Palace a lifeline in the second leg of their play-off semi-final.

Sunderland had looked like certain winners as Palace were reduced to ten men while trailing 2-0, but Powell's late intervention forced extra-time.

After winning Friday night's first leg 3-2, Palace could have extended their lead as Sunderland started slowly but, as half-time approached, Kyle and Stewart delivered the perfect one-two to put Sunderland in the driving seat.

Jason McAteer had done little of influence in the rest of the first half but, in the 42nd minute, he floated a pinpoint cross into the area for Kyle to chest the ball down perfectly before smashing an unstoppable close-range drive past Nico Vaesen.

The Scotland international might not be the most aesthetically pleasing of strikers, but his pinpoint control showed there is far more to his game than the aerial tussles for which he is renowned.

Kyle's strike partner Stewart is normally the one associated with timing and touch in the box but, ironically, it was his heading ability that sent Sunderland into an aggregate lead in first-half stoppage time.

McAteer sent over another measured centre from the left and Stewart didn't need to break stride as his thrusting run ended in an inch-perfect header that gave Vaesen no chance at his near-post.

Sunderland's play-off history is littered with second leg comebacks and, after overhauling an identical one-goal deficit against Sheffield United in 1998, the Black Cats had history on their side going into last night's decider.

But McCarthy's team selection underlined their need to succeed at both ends of the field. Irish international Sean Thornton, one of the club's most visionary figures on his day, replaced Carl Robinson in midfield.

And, after being taken to the cleaners by the lively Julian Gray at Selhurst Park, right-back Darren Williams found himself dropped in favour of Joachim Bjorklund despite being the only survivor from the Black Cats' most recent play-off campaign.

Iain Dowie opted to name an unchanged line-up following Palace's 3-2 win on Friday night, but the Eagles boss was left with the difficult decision of whether to sit on his side's one-goal cushion or urge his players forward in the hope of getting a potentially decisive goal.

Dowie's choice was evident from the kick-off as Palace launched three dangerous attacking raids within the opening three minutes.

The first two ended with the Black Cats' backline scrambling the ball away, but the third culminated in Estonian goalkeeper Mart Poom making a fine smothering save from Gray after the winger had been sent clear by Michael Hughes.

Sunderland barely touched the ball in the opening skirmishes and they were almost made to pay for their slow start three minutes later.

Andy Johnson wriggled free down the left, but midfielder Aki Riihilahti sent his header crashing against the upright with Poom well beaten.

The home side needed something to get them into the game and, while skipper George McCartney's skidding strike didn't threaten to beat Vaesen, it at least gave the Black Cats a foothold in their opponents' half.

Sunderland were still making far too many unforced errors though, with an abundance of heart occasionally winning out over more intelligent use of the head.

Bjorklund highlighted the sense of panic when he rushed a routine header and allowed Johnson to whistle a crisp 20-yarder narrowly past the left-hand post.

But there is nothing like a goal to settle the nerves and the Black Cats found the perfect antidote to their jitters three minutes before the break. Kyle's strike was rapidly followed by Stewart's and suddenly it was Sunderland who were left with the question of whether to stick or twist. For much of the second half they did the former with their back four increasingly pushed back onto the edge of their own penalty area.

Gary Breen won a succession of vital headers against Neil Shipperley and, when the Palace skipper found himself in a rare opening shortly after the hour mark, he could only send a dipping half-volley well over the crossbar.

The Black Cats were playing a dangerous game and, as the pressure continued to mount, substitute Darren Powell came close with a looping header from Wayne Routledge's corner.

Gray also shot wide as full-time approached but, with Palace committing more and more men forward, Jeff Whitley shot tamely when presented with a great chance to make things safe.

Gray was then dismissed for two bookable offences following a crude lunge on McAteer, but there was to be a sting in the tail as Powell headed in Shaun Derry's corner.