German Adrian Sutil has been slapped with a five-place penalty on the starting grid for Sunday's Japanese Grand Prix after having to replace his gearbox following a crash in the final free practice.
Sutil's Force India car spun into a wall exiting the treacherous "Spoon" curve after just eight laps of Saturday's morning session, breaking off his front wing. Once the car had been returned to the garage, mechanics discovered the gearbox had been damaged too.
As the current unit had not completed the mandatory five races, fitting a new one results in an automatic five-place penalty.
"It's not been an easy day," said Sutil, who had qualified 17th fastest in Suzuka. "I made a mistake this morning, damaged the car and we had to change the gearbox.
"I have to say a big 'thank you' to the team for getting the car ready in time for qualifying because they had a lot of work to do during the lunch break.
"In Q1 the car was quite difficult to drive. I didn't feel comfortable and was missing the grip to be competitive. All I can do now is look forward to the race and hope we have a better day.
"With the grid penalty I will be starting near the back so I need to try and deliver consistent race pace and hopefully move towards the points."
Meanwhile, Caterham's Charles Pic copped a drive-through penalty for passing through a red light at the pit exit during the first part of qualifying, compounding a 10-place grid penalty incurred after earning a third steward's reprimand in South Korea last week.
The Dutchman, who qualified in 20th, must serve his drive-through penalty within the first five laps of Sunday's race.
Saturday saw more smoke and flames at Suzuka, the most hair-raising incident involving Esteban Gutierrez, whose Sauber caught fire after he had returned to the pits during qualifying and was being wheeled back into the garage.
"I just saw it and jumped out," said the Mexican after his close shave. "The guys had everything under control and I was relieved that I was able to continue my qualifying."
Sauber's head of track engineering Tom McCullough said: "We did have a fire during Q1 from some unburnt fuel, which meant we had to change our plans slightly, but there was no damage to the car and we were able to continue."
Gutierrez's team-mate Nico Hulkenberg qualified seventh.
"We knew we could fight for the top 10 but seventh is a nice surprise," said the highly-rated German. "It was very tight, everything had to fall into place and I think we managed to do that."
Williams were fined 60,000 euros after Pastor Maldonado's left-rear wheel fell off in opening practice on Friday.