The Everton striker, who scored five goals in 14 games for the Eagles earlier this term, has rejoined on loan until the end of the season.
Vaughan will vie with fellow January recruits Steffen Iversen and Jermaine Easter, as well as Pablo Counago, for a place in attack.
Defender Anthony Gardner suffered a head injury against Bristol City last weekend but managed to complete the game and will be patched up again.
Midfielders Darren Ambrose (hamstring) and Alex Marrow (ankle) came through their comebacks against the Robins unscathed, so full-back Lee Hills is now the only absentee with a knee injury.
Goalkeeper Julian Speroni will make his 200th appearance for the club.