I filed an I-90 in July 2002 when my 10-year green card expired...it fell through the cracks somehow and I never got a new green card (had to keep getting "temporary" stamps in my passport every year instead, which was such a PITA.) I finally said "sod it" and got my US citizenship in 2005 instead...having a passport was much better than a new green card!
But that's a pretty off-the-wall case, the rest of my family filed I-90s too and got their cards renewed without a problem.
Congrats to your hubby Marlespo!