The schoolteacher, who left Ramsay Street last year after breaking up with wife Libby (Kym Valentine), will feature in a shock scene featuring a new twist in Steph Scully's baby storyline.
In an episode which airs in Australia next week, fans will see Steph paying a visit to Dan - played by Brett Tucker - and announcing that she wants him to have permanent custody of their newborn son.
Speaking to TV Week about the surprise scene, Steph's portrayer Carla Bonner explained: "We filmed it prior to Brett leaving the show back in 2009. He loved the fact that Dan Fitzgerald still has such a presence in the show. Even though the character has physically left, his legacy lives on."
Discussing how fans may react to Steph's choice, the actress said: "I think it will divide viewers. A mother giving up her baby is a massive decision to make and a huge sacrifice. But ever since she fell pregnant, Steph's decisions haven't made her a fan favourite, and this won't help save her reputation!"
The new development follows a long-running storyline which saw Steph and Toadie (Ryan Maloney) staging a sham reunion in a bid to prevent anyone from finding out that Dan was the father of the child.
Asked how she felt about the latest twist, Bonner replied: "Honestly, I had trouble with it at first. Ryan and I took a lot of convincing to take this storyline on and now, with Steph giving the baby away, I had even more trouble comprehending it. I can understand why the producers took this path, though. There is a method to their madness!"