Veteran striker Rodney Jack sent last season's runners-up Wigan crashing out of the Carling Cup as Crewe beat the Premiership side 2-0 at Gresty Road in the second round.
And while Paul Jewell's side featured summer signings Denny Landzaat and Kevin Kilbane and substitute Emile Heskey, they were unable to save themselves as the League One Railwaymen held firm and Nicky Maynard secured the win with a late second.
Everton had to dig deep to beat plucky Peterborough at London Road.
Phil Neville's deep cross was headed goalwards by James Beattie but Jude Stirling deflected the ball past his own goalkeeper Mark Tyler to give the top-flight side the lead.
Posh drew level after 56 minutes when the Toffees failed to clear Trevor Benjamin's header before it crossed the line.
But Australia international Tim Cahill forced home a winner in the 87th minute after sterling work by striker Victor Anichebe.
Premiership high-fliers Portsmouth were rarely extended en route to a 2-1 win at Mansfield.
Summer signing Manuel Fernandes scored on his debut with an excellent early strike after five minutes against the Stags and Matthew Taylor doubled the lead with a speculative long-range shot before the half was out.
Pompey conceded their first goal of the season when Danny Reet showed a cool head to pull one back for Peter Shreeves' side but it was not enough to mount a comeback.
Christian Nade's superb solitary goal gave Sheffield United an uncomfortable victory against Bury at Bramall Lane.
Bolton ground out a 3-1 victory against stubborn Walsall at the Bescot Stadium.
Substitute Kevin Nolan put Bolton ahead in the 68th minute at the Bescot Stadium after good work by Sam Allardyce's side on the break.
The Premiership side had wasted several chances and were made to pay when the Saddlers equalised six minutes later through veteran striker Martin Butler.
Ivan Campo got the winner two minutes from time, though, and Nicolas Anelka wrapped things up in added time.
Having laboured for most of the game at The Valley Charlton finally made their superiority count as England striker Darren Bent broke the deadlock to help them beat Carlisle.
Both sides had chances but The Addicks made hard work of their evening before the former Ipswich man spared his side's blushes.
West Brom needed two penalties to beat Cheltenham 3-1 at The Hawthorns.
Kayode Odejayi struck seconds into first-half injury time from the edge of the box as West Brom failed to exert their authority.
Cheltenham failed to clear their lines and Ronnie Wallwork scored with a diving header early in the second half.
Albion needed a penalty for handball to take the lead, Nathan Ellington converting after an alleged offence by Brian Wilson and Stuart Nicholson added another, also from the spot, after chief tormentor Jason Koumas was brought down.
Leeds beat Barnet 3-1 at Elland Road to lift the pressure on manager Kevin Blackwell as Robbie Blake opened the scoring before two from Ian Moore.
Norwich eventually overcame Rotherham at Millmoor to win 4-2.
Peter Thorne gave Norwich a sixth-minute lead but the Millers responded through Michael Keane (24)
The home side then took the lead early in the second half through Lee Williamson's penalty after Jason Shackell's foul on Will Hoskins. This time Norwich equalised, Ryan Jarvis tapping in after a goalmouth scramble before Craig Fleming edged the visitors in front.
Jarvis added a fourth in added time.
Southampton enjoyed an emphatic 4-0 win over Millwall at The New Den, Bradley Wright-Phillips scoring twice.
Leicester beat League Two newcomers Hereford 3-1 at Edgar Street in a game which ended with each side reduced to 10 players.
QPR's interest in the competition was ended by a 3-2 defeat by Port Vale in the Potteries.
MK Dons beat Championship hosts Barnsley 2-1 while Luton romped to a 3-0 win at Brentford. Southend came from behind to beat Brighton 3-2.
Premiership side Watford needed penalties to beat League Two Accrington at Vicarage Road following a goalless match.
After a sterile 90 minutes and extra-time both sides scored their five penalties.
Accrington, promoted back to the Football League last season, missed their sixth as Peter Cavanagh's kick was saved by Hornets goalkeeper Richard Lee. Watford failed to capitalise as James Chambers blasted too high.
Lee made another save, this time from Paul Mullin, to put Watford in a winning position as Anthony McNamee scored his side's seventh kick.
Top flight newcomers Reading also needed penalties to win as Darlington capitulated in the shoot-out after a 3-3 draw in open play.
The League Two visitors took the lead through Simon Johnson's penalty. Leroy Lita levelled and was forced to equalise again after Julian Joachim's first goal.
Former Aston Villa striker Joachim put the lowly north-east club ahead again after 52 minutes with an instinctive finish only for Peter Mate to take the game to extra-time with a mis-hit strike after Darlington were reduced to 10 men due to David Duke's sending off for a professional foul.
And Darlington missed two penalties in the shoot-out - Darren Holloway and Neil Wainwright - and though striker Kevin Doyle also missed for Reading, Andre Bikey scored the final kick to record a 4-2 shoot-out win.
Birmingham needed three goals in extra-time to beat League Two visitors Wrexham 4-1 at St Andrews.
Prolific forward Chris Llewellyn made Wrexham's pressure tell after 28 minutes as he rifled home after Danny Williams' knock-down.
Cameron Jerome ensured Birmingham ended the half level as he headed Gary McSheffrey's cross past Michael Ingham and in the second half DJ Campbell wasted an opportunity from the penalty spot as the game then went into extra-time.
City pressed forward and Gary McSheffrey made the pressure count as he hammered home the winner from 25 yards after 102 minutes and followed it up with a second to kill the game off in the second half of extra-time.
Substitute Nicklas Bendtner completed the scoring in the last few minutes.
Hull beat Hartlepool 3-2 on penalties after neither side could break the deadlock in 120 minutes.
Jon Daly missed the Pools' decisive kick before Andy Dawson converted to seal his side's passage to the third round.