Casillas, dropped for the second game in a row, came off the bench early on to replace sent off goalkeeper Antonio Adan.
Real were eventually able to see off the challenge of Real Sociedad 4-3.
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Since Guus Hiddink arrived at the helm, Chelsea have improved considerably after a tricky start to the campaign.
Newcastle United are staring down the barrel of relegation to the Championship for the second time in the past eight years.