Thanks Reba. I am guessing that he will be getting a TN visa. Regarding SSN, he does have a SSN from previous employment, but having a SSN doesn't mean that you have to pay tax I hope.
Depends on where they've paid him really, if he got a W-2 then he might need to file a 1040NR. If he was paid in Canada for the work in the US, and he gets a T4, there isn't anything to worry about really.