Hugh slid from the top of one of the Opera House's 'sails' on a high-tension 100m-long steel wire, and was meant to drop gracefully onto the stage. Instead he smashed into one of the set’s lights.
But the action man, who performed a similar stunt last year in Sydney to promote his Wolverine film, was successful lowered to the stage and got over the pain with what appeared to be a glass of red wine.
Local news reports say the brakes on the 'Flying Fox' device failed.
He was also comforted by Oprah after the stunt.
He was also well enough to be interviewed on stage afterwards in front of a 6,000-strong crowd by the chat show queen.
Hugh, who arrived in Sydney from New York just hours earlier with his family, slid down a cable from the top of the Opera House onto the stage after U2 star Bono was interviewed by Oprah.
Oprah has filmed two of her shows today at the Opera House to mark the final season of her talk show.