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It was Healy's second such injury in ten months, occuring in just his eighth week back in training.
The Corkman suffered his initial break last December, coming off the worst in an 80th minute tackle with Coventry City's Moroccan midfielder Youssef Safri at Highfield Road.
The 13-times capped international is currently in plaster and specialists have confirmed that he should make a full recovery.
Sunderland's head physio Pete Friar told the club's website: "The fact that Colin suffered a refracture was a shock and surprise to us all, particularly as he had experienced no pain or discomfort during the last six weeks or so.
"However, failure rates of tibial fractures are well documented and recognised and footballers are not immune to these statistics.
"Colin now has his leg in a plaster and although the tibia has failed to heal first time round, the consultant has said that it would be extremely unlikely that he will be a victim of these statistics a second time."