I went through this company... http://www.whitecardexpress.com.au/
You do the test online with no requirement to sit in on a class, zero chances of failing and you obtain a WA white card which is valid across Australia.
I think it may be the end for him. Should the company cancel his 457 before the PR comes through, he'll have to start from scratch and find a new 457.
The PR under the ENS takes about 5-7 months so it may come through soon.
Would I be correct in saying that your breaking the conditions of your 457 by setting up a company and having a second income as you can only work for your 457 employer and 457 employer only?
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I can answer your first question: You can claim it back after departing Australia. You need to send your super fund company proof you've departed (copy of your departure passport stamp)