Yes the record must still be disclosed even if expunged.

Contact USCIS to inquire directly about your case as there are backlogs and delays.

Yes a valid passport should be sufficient for travel purposes.

Better to return after more than 6 month absence.

Best to discuss your specific history with an attorney in private.

Yes she may do so and apply for a tourist visa.

He should apply for a reentry permit for any trips longer than 6 months.

Best to contact NVC directly using their online portal.

No not with the pending removal case.

No this is not advisable even if GC is issued through marriage.