Born in Abergele, Conwy, Vaughan began his career as a trainee at Crewe Alexandra. Initially an attacking full-back, manager Dario Gradi turned him into a left-sided midfielder. Vaughan made his debut on 19 August 2000 in a 0'0 draw with Blackburn Rovers. It was to be his only appearance in the 2000'01 season. The following season he made 16 appearances and scored his first goal for the club on 26 January 2002 in a 4'2 win over Rotherham United in the fourth round of the FA Cup. Crewe finished in 22nd place in Division One and so were relegated to Division Two.
The 2002'03 season saw Vaughan make 40 appearances, scoring four goals as Alex finished second in the Second Division and so were promoted to the First Division. He also scored the first goal in an 8'0 win over Doncaster Rovers in the Football League Trophy on 10 December 2002. Sixteen days later he scored his first league goal in a 4'0 win over Cheltenham Town at Whaddon Road.
The 2003'04 season saw Vaughan make 33 appearances as Crewe finished 18th in the First Division. The following season he made 48 appearances and scored six goals in what was now the Championship as Crewe avoided relegation only on goal difference. In 2005'06 Crewe were relegated to League One, with Vaughan making a total of 36 appearances and scoring five goals.
Back in League One, Vaughan made a total of 35 appearancs in 2006'07, scoring four goals. He played one game at the start of 2007'08; then, on 17 August, Crewe accepted a £300,000 bid for him from Spanish side Real Sociedad.
The transfer was completed on 23 August 2007, after Vaughan had held talks with Chris Coleman, who had been appointed as manager of Real Sociedad two months before following their relegation to the Segunda Divisi'n from La Liga. Coleman resigned as manager on 16 January 2008 and Vaughan was to make only nine appearances, scoring one goal, as Real Sociedad finished fourth in the 2007'08 season and so missed out on promotion to La Liga.
On 4 August 2008, Vaughan moved back to England, joining Championship side Blackpool for a fee of £200,000. He signed a two-year contract, with the option of a further year.
He made his debut for the Seasiders on 9 August 2008 as a second-half substitute in a single-goal home defeat to Bristol City at Bloomfield Road. His first goal for the club came in a 2'3 home defeat to Doncaster Rovers on 7 February 2009. He made a total of 35 appearances that season.
His first goal of the 2009'10 season came in a 2'0 win over Plymouth Argyle at Bloomfield Road on 17 October 2009. Following his performance in the 2'0 home win over Reading on 20 January 2010, he was named in The Championship "Team of the Week".
In week eleven of the 2010'11 Premier League season, Vaughan was named in the Team of the Week, alongside teammate Neal Eardley.
On 26 February 2011, Vaughan captained Blackpool in Charlie Adam's absence. On 13 June 2011, it was announced that Vaughan had been unable to agree a new contract with Blackpool and was therefore leaving, citing that he wished to continue playing in the Premier League if possible.
On 8 July 2011, Sunderland signed Vaughan on a three-year deal after agreeing personal terms and passing a medical. Vaughan made his debut on the opening day of the season, coming off the bench against Liverpool. After several games on the bench Vaughan replaced Lee Cattermole in central midfield at home to Stoke City, offering a man-of-the-match performance in Sunderland's first victory of the season, a 4-0 win. He scored his first goal for Sunderland against Blackburn on 11 December 2011 in a 2-1 win for Sunderland. Vaughan scored his second goal for Sunderland as they thrashed Wigan 4-1 at the DW Stadium on 3 January 2012.
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|Date of Birth:||18/02/1983|
|Place of Birth:||Abergele, North Wales.|
|Former Clubs:||Crewe Alexandra,Real Sociedad (Spain), Blackpool.|
|First Cap:||USA 2002-03.|
|Age at First Cap:||20 years 97 days|
|Total Caps/Goals:||35 / 1|
|U21 Caps/Goals:||8 / 3 Goals. 1|
|U19 Caps/Goals:||2 / 1 Goal|