Had precious little to do as Sunderland failed to really test him with any effort of note until late on when the howler of all howlers almost cost his side in extra time. Saved twice in the shootout but it wasn't enough.
Led the United backline well with Vidic missing, though communication was sometimes lacking. Stole a march on O'Shea to nod home the opener.
Struggled to contain Borini but got forward well himself to support attacks. Excellent cross created opportunity for Fletcher though persistent fouls could have caused more problems. Missed the crucial penalty.
Caught out on occasion, most strikingly when he allowed Johnson pass to drift over his head for Borini effort in the first half. Still not convincing in the air despite obvious height. Also lucky to avoid red card as Fletcher looked to run through.
Looked to get forward on the left but ran down too many blind allies and crossing was poor. Troubled by Johnson everytime the winger got the ball at his feet, though an excellent block in the second half denied the England man.
Not quite the passing masterclass that many know he can produce but he kept the ball well enough in the middle of the park. Still the best of United's midfield, though his substitution through injury will cause some concern.
Handed the captaincy but was caught on the ball too many times by the tenacious Cattermole. Did well to get round the back of the Sunderland defence to hit the post in the first half.
Yet another display to suggest he will mature into a world-class talent. Left Alonso for dead on more than one occasion and delivery was consistently good. Wasted a good chance midway through the second period.
First touch let him down too often. Saw an early header pushed away by Mannone before spurning a great chance to seal the tie in extra time. Kept the hosts in it with an instinctive late finish at the far post.
Not a natural at playing behind the striker but his pace was a constant threat running from deep. His hooked volley created Evans' headed opener.
Allowed time in a central area and looked bright when he got himself on the ball. Final ball was sometimes lacking as he was replaced in the second half.
Parried early Hernandez header well and had no chance with either goal. Did well put under pressure by some questionable backpasses from team-mates before two saves in the shootout secured a place at Wembley.
Gave the ball away a little to often as his long balls for Fletcher were picked off with ease. Saw a first-half header cleared when goalbound.
Allowed Evans to run free at the back post for the opener and was poor throughout on his return to Old Trafford. Passes into midfield weren't good enough.
Never got to grips with the impressive Januzaj on the United right. Was better going forward as he and Borini combined well. Almost snatched an equaliser with volley across De Gea's goal, but made no mistake in the shootout with a fine finish.
Couldn't get forward as much as he would have liked despite not really having anyone in particular to mark. Switched off as Fletcher hit the post in the build-up to the opening goal before his speculative effort almost secured passage to Wembley.
Won numerous tackles in midfield as he showed his tenacity can be put to good use on occasion. Passed backwards a little too often.
Looked the most comfortable on the ball of any of the Sunderland players as he regularly found himself in space. Shooting was the only aspect of the game he seemed to find difficult.
Kept the ball well enough in the middle of the park as he always looked to keep his side moving forward. Never able to make any incisive passes, however.
A real threat when he was given the opportunity to run at Buttner. Unbelievable pass almost led to Borini wonder goal in the first period.
A real danger on the left-hand side as his trickery and pace troubled Rafael. Unfortunate to see long range effort fly over before he played Evans onside for the opener.
Did his best to find space but was left isolated up front on too many occasions. Inability to hold the ball up led to numerous attacks breaking down.
Replaced the limping Carrick in extra time and helped shore up United's midfield if little more.
Replaced Buttner late on in normal time and showed good energy and pace as others began to flag.
Pace caused plenty of problems for Alonso after he replaced Kagawa midway through the second half.