Overstayed tourist visa by more than one year but was not officially barred for 10 years

She doesn't need a formal adjudication that she is subject to be subject to the ten-year bar for the one-year overstay, and the fact that she may also have been subject to a five-year expedited removal bar doesn't absolve her of the ten-year bar. If she accrued one year of unlawful presence after the expiration date of her visitor visa and then departed, there is nothing hypothetical about her ten-year bar.

We would need to know more about what exactly happened at that attempted return in '02 - if they turned her around under expedited removal, there may be something here which gives her bigger problems than the ten-year bar. If someone lacks the required nonimmigrant intent, they may be refused entry but will often (though not always) be given the opportunity to simply withdraw their application for entry rather than be placed in expedited removal and become subject to the five-year reentry bar that this carries. If she obtained a visa through fraud, that's another matter entirely.

A FOIA request may or may not get you the info that's needed, but it's worth a shot. Even when the ten-year bar expires in 2011, she might still have some sort of problem that prevents entry. More research is needed here.