Here's a couple more pieces of the puzzle.

He's a Ukranian Citizen, who holds a ukranian passport so needs a visa in his passport to travel into the USA, even as a permanent resident (landed immigrant / IMM1000 / whatever).

Ironically he's even taken the Citizenship test and passed. He's (hold it - guess what ?) yup, waiting for paperwork.

We did contact the Consular offices abroad, and are attempting to get him back through LAX where he can pick up a TD, but that is an ordeal in itself. They need to interview in the morning, and can't issue a TD until the afternoon (after 2pm).

I'm fankly amazed at this level of silliness.

American Airlines has let me board a plane back to Canada within the last 30 days using an INSPASS clearly stamped "not a visa or passport" at checkin.

YMMV.
Sigh.
Ben.