He chipped in for birdie behind the 16th green and two-putted for birdie on the 18th for a 69 to finish alone in second, moving him up to No. 47 to get into Doral.
"I hope I can bore him to death - down the fairway, on the green, lots of birdie chances, " said Casey.
The highlight of the 37-year-old's late surge came when he hit a driver on to the par four 16th green to set up a birdie.
From a fairway bunker, Woods hit 8-iron from 178 yards to the middle of the green for a two-putt birdie.
He started his round on the 10th and was three under through his first 10 holes before a 25-foot birdie on the third green sparked a superb last seven holes, where he picked up four further strokes.
Woods held the green with his approach and sank a birdie putt.
Watson missed a 12-foot birdie putt on the final green which would have earned him a playoff, but Austin's fadeout was more disappointing.
Weekley's 22-foot eagle chance at No. 1 stopped about 6 inches from the cup before he chipped in for another birdie from behind the third green.
Just as they walked off the green, Lee's third consecutive birdie moved her to 10 under, and Jutanugarn's fifth birdie in six holes also got her to minus 10.
Lingmerth finished a wild day with an 8-foot eagle putt on the par-5 16th and a 10-foot birdie on the island-green 17th to reach 12-under par when the third round was suspended because of darkness.
Although the 27-year-old, bidding for his third US Open crown in four years, bogeyed the fifth after his approach spun sharply back off the front green, he recovered with an easy birdie-four at the sixth.
Annes, when he drove into a car park and then chipped onto the green before sinking a 30-footer for birdie.
But he made the green in two at 17 to make the birdie that ensured his presence for the weekend - and another chance of the good night's sleep (and a touch of medication) he needs to shake of a heavy cold.
But at the next, Casey holed a monster 25-foot birdie putt from the back of the green to take the title.
Garcia hits an excellent second shot on to the green but misses a 20-foot putt for a birdie and has to settle for the half point.
Instead of laying up, he drilled a 5-wood into the bunker left of the green, setting up a simple sand shot and a birdie he didn't even need.
Byrd's round was his best of the year, and he capped it off with a string of birdies that began with a 25-foot birdie putt on the par-three sixth green and ended with a wedge to six feet of the pin on eight.
Justin Leonard fought back from four down to level with Jose Maria Olazabal and then holed a 45-foot birdie putt and the American team wildly celebrated on the green as though they had won the cup.
Els makes the green with his tee-shot and then hits a stunning 30-foot birdie putt to go three up with eight holes to play.
But Kaymer responded by following him in from 25 ft for birdie, then made his own outrageous 40-footer from left of the 17th green.
Garcia finds the edge of the green with his second shot, but over-hits his third and then misses a 15-foot birdie putt.
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