Emmerdale’s Ryan Hawley has broken his silence on his return to the ITV soap as the show bosses reveal the extreme lengths they took on keeping his storyline under wraps. 

The actor, 39, took on the role of Robert Sugden in The Dales back in 2014. 

Ryan left Emmerdale back in 2019 after his alter-ego was involved in the murder of Lee Posner (Kris Mochrie). 

Robert was sent to prison for accidentally killing Wendy Posner’s son Lee after raping his sister Victoria Barton (Isabel Hodgins). 

On Wednesday fans went wild as Robert gatecrashed his ex Aaron Dingle’s wedding to his long-lost brother John Sugden (Oliver Farnworth). 

Speaking to The Mirror about his epic return, he said: ‘The secret is out today!

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Emmerdale’s Ryan Hawley has broken his silence on return as show bosses reveal extreme lengths on keeping storyline underwraps

On Wednesday fans were shocked as Robert  (pictured) gatecrashed his ex Aaron Dingle’s wedding to his long-lost brother John Sugden (Oliver Farnworth)

‘My character is returning permanently and not just for Aaron and John’s wedding. I am back for good, and I am so excited to be playing Robert again.’

The star has been living in Brazil with his family over the past year and never thought it was the ‘right time’ to reprise his role.

But something had changed to make him return.

And the show pulled out all the stops to make sure that the return was a surprise and kept under wraps for as long as possible.  

He explained: ‘My scripts have had Marco on them, rather than Robert, and so much effort has been put into it. 

‘I have been coming in via a secret entrance, so nobody could see me arrive, and it has been very hush, hush. 

‘I have also got driven in by one of our very trusted esteemed transport seniors to make sure it stayed a secret, and so much hard work has been put into it logistically.’  

Aaron (Danny Miller) and John (both pictured) were shocked to see him appear during their special day after being in prison

Robert was sent to prison for accidentally killing Wendy Posner’s son Lee (Kris Mochrie) after raping his sister Victoria Barton (Isabel Hodgins, pictured)

Read More Emmerdale fans go WILD as Robert Sugden RETURNS to gatecrash ex Aaron Dingle’s wedding

Speaking on Thursday’s episode of ITV’s Lorraine, Ryan confirmed that he isn’t going anywhere. 

He told the host: ”It’s indefinite. 

‘Robert is back. He’s coming back to try and win Aaron back. 

‘He’s trying to stop John.’ 

Ryan has had a very popular acting career since shooting to fame in the 2000s. 

He landed a role in Life Is Wild in 2007, followed by another in Doctors the following year.

He also played Will in Survivors the same year. 

Before starring in Emmerdale, he played Andy Thatcher in Devil’s Pᴀss, John Van Ert in Father Brown and Jack Thayer in тιтanic. 

After leaving The Dales he starred in two episodes of Silent Witness as Michael Robson. 

He also took on the role of Sid Crabtree in All Creatures Great and Small. 

Last year he starred in five episodes of Casualty as Jamie Cleveland. 

Hawley has been living in Brazil with his family over the past year and never thought it was the ‘right time’ to reprise his role (pictured on the show in 2018)

Ryan is also a stage performer, having been in The History Boys, Letting in Air and You May Go Now.

On Wednesday night, viewers were over the moon with Robert’s epic return. 

Taking to social media, one said: ‘Robron back in the year 2025 after six years I’ve never been f*****g happier;

‘I’m sorry, but to be gone six years and turn up looking this GORGEOUS?! HIS POWER!!!’

‘Robert: Miss me. Everyone: YES;’

‘ROBRON IS BACK IN THE YEAR 2025 ROBRON STANS HOW WE FEELING.’

Speaking about the reaction on Lorraine on Thursday morning, Ryan said to the Scottish host: ‘Some of the reactions, I was like “wow”. 

‘I was on a train, coming here to see you! I’ve seen some on social media, great response – and some people here! 

‘It’s such a good year going forward. Towards end of year… I’m so excited where the show is going. It’s a great time to be involved in it.’ 

Emmerdale airs on ITV.  

‘Robert is back. He’s coming back to try and win Aaron back. He’s trying to stop John’