Thanks for reply ksand24!
To answer your questions - I don't have permanent residence in UK. I hold Polish passport only and Im excercising EEA Treaty Rights.
He've applied for 5 years Residence Card using my Polish passport.
To work in UK he needs National Insurance Number which he doesn't have plus he received a letter from Home Office that he cannot work until they change it.
You've done exactly the right thing, applying for the 5-year EEA Residence Card. The only problem is that because he entered the UK as a visitor, he doesn't have any proof of his automatic right to work in the UK.
Technically he is allowed to work and legally he doesn't actually need a National Insurance number to start work, but because he doesn't have the EEA Family Permit, he is unlikely to be able to get a job... since the companies will want to see his proof of right to work, which he doesn't have.
If he had applied for the free EEA Family Permit in the US before moving to the UK, he could have worked immediately, because the permit would explicitly state that he can work. Then he could have applied for the EEA Residence Card and continued to work while it was processing.
Do you know if we need to prove that we have 18.000 saved on my account or do I need to go for an interview to Home Office as his sponsor?
No, just ignore this.
This does not apply to you after all, because you do not hold permanent residence and therefore are not eligible to sponsor him for that visa anyway.
The £18,600 requirement is only for people who are UK citizens or who hold permanent residence in the UK and wish to sponsor their partner for a UK visa.
As you are an EEA citizen, you don't need to apply for a UK visa because he already has the right to live in the UK (also he would not be eligible to apply in the UK anyway) - and that's a very good thing, because he will have more rights in the UK as the spouse of a Polish citizen than as the spouse of a UK permanent resident/UK citizen. Plus it's about £5,000 cheaper to apply for EEA permits and residence cards than to apply for UK visas.
You said that he could withdraw his application but then he'd have to leave UK and apply for new visa. Do you think he could go to Poland and do it from there rather than going back to US now?
He can apply for the EEA Family Permit from any country he likes (it's not a visa though, it's just confirmation of a right he already has)
However, you would need to check on the processing times in each country to see whether it's worth going somewhere other than the US, since they can vary considerably:
https://www.gov.uk/visa-processing-timesCurrently in the US, 51% of applications are processed in 1 week and 95% are processed in 3 weeks, but in Poland, only 9% are processed in 1 week and 95% of applications are processed in 3 months... that's a big difference!
For the US:
51% of EEA Family Permits are processed in 5 working days,
82% in 10 working days
95% in 15 working days.
100% in 30 working days
In Poland:
9% processed in 5 working days
78% in 10 working days
90% in 15 working days
93% in 30 working days
93% in 60 working days
96% in 90 working days
96% in 120 working days
100% in ?
(they obviously hadn't all be processed at the time of publishing)
So, if he withdrew his application and went back to the US to apply for the EEA Family Permit he might only have to be there for maybe 4 weeks, hopefully less. But if he applied in Poland, he could be stuck there for up to 3 months (and they would have his passport, so he couldn't leave).