Ready likely means that the passport is ready for pick up after possible approval.

Yes with the appointment notice should suffice.

Best to travel within the contiguous US.

The system may not be reflecting real time and may be in error.

This is not advisable as your first marriage will be scrutinized.

You may attempt this but it is highly unlikely that an expedite request will be approved.

Yes, this prohibition will affect the approval.

Such a request requires a review by an attorney.

Yes, her green card should be sufficient for entry.

Yes, it is fairly normal to not receive a response at this time.