Here is an update after talking to two lawyers (current and future employers) and talking to IRS.
>> All pages from all passports (except the current one, which they already have)
Lawyer recommended that I submit fresh copy of current passport as well. Especially as travelled abroad while waiting for GC.
>> Back and front of all I-94 prior to June 2003 (one of my entries to US). I do not have B1/B2 I-94 for 1999-2001, but do have all H1 I-94 from 2002 and later.
Lawyer says that it's OK to miss old I-94. However, all newer I-94, including extension of status should be included. We will have to explain that those old I-94 were returned back to DHS upon exit from US, and so we cannot obtain copies. We will also list all US entry/exit dates and highlight relevant stamps in the copies of passports.
>> All diplomas, certificates and transcripts - school, college, university. I have all three certificates/diplomas, but no transcripts from school and college.
It seems my university transcript covers college time as well (maybe because I transferred). Lawyer said it's OK not to have school transcripts, but advised to order them, just in case USCIS will really want it in the future.
>> Copies of all 1040 (signed and dated), along with schedules for Profit/Loss from Business, Self-Employment tax and Treaty-Based returns
Since 1040 were e-filed, I will have to include some proof of e-filing.
>> Original IRS income and return transcripts for all years
IRS Account Transcripts are available for all years. However, IRS Tax Return Transcripts are available only from 2004. Since 2002 and 2003 are not available, I've requested photocopies (yes, paid $78 for photocopies of e-filed returns, welcome to government's world : ) We will file a copy of this request and cleared check, showing that it will take 60 days to get photocopies.
>> My wife and son received RFE because doctor forgot to write TB skin test results.
Lawyer advised to go for a new TB skin test, and then do a fresh chest X-Ray if skin test is positive. She did not recommend to use old TB skin test results.
Other notes:
I do not have any US-based education.
Yes, they asked for ALL I-94. My PD is March 2006.
There are two explanations why they do it:
1. Burkino from trackitt.com thinks that newly hired USCIS AO's want to use all their new knowledge, or they want to impress their supervisors, or both.
2. Lawyer told me she sees more of these RFE's now and thinks it relates to CYA (cover your ass) work mode. They now approve applications without all security checks, so AO's try to exercise extra-due-diligence to cover themselves in case future NC results would be bad.
Disclaimer: this is not a legal advise, talk to your own lawyer : )