Sullivan was a multi-sport athlete at Fenwick High School, lettering in football, wrestling, and bowling. In 1995, Sullivan was one of the top three offensive lineman in the country achieving All-American and All-State honors helping the Friars reach a 12-1 record. He decided to accept a scholarship to play college football for the Illinois Fighting Illini.
Sullivan graduated from the University of Illinois with a degree in Recreation, Sport and Tourism Management.
Sullivan was selected in the fifth round of the 2001 NFL Draft by the Buffalo Bills. In 2004, he played for the New York Giants and the New England Patriots. Sullivan retired from football in 2007 after playing for the Chicago Rush in the same year.
He currently is involved with many charitable causes in the Chicago area. He serves the Director of the Chicago NFL Alumni Football Camp, coaching high school aged children. Sullivan also coached for the Chicago Bears Youth Football Camp coaching children ages 6–13. Sullivan also served the NFL Alumni its executive vice president of the Chicago Chapter and as a vice president of the National Football League Former Player's Association - Chicago Chapter. On July 10, 2008 North Park University announced that Sullivan would be the football team's new offensive line coach.
Sullivan has held Vice President position of the NFL Retired Players Association - Chicago Chapter. He also owns post-graduate prep school, Midwest Prep Sports Academy. Sullivan is married to former U.S. national level gymnast, Veronica Saldana Sullivan.