Hello!
On the local travel, I don't think there will be any problem even if the extension visa has not come out yet (but of course I do not advice that your husband stay without a valid documentation in place
) at the local airport they only ask for the passport to verify the identity of the name in the air ticket, but they don't scan it (just based on my own experience when we travelled to Toronto from Calgary, no passport scanning happened if my memory serves me right)
With the PR application, I don't think sending it now will help that much because currently I think it takes 5-6 weeks for Immi to send an AOR - which effectively gives someone the 'implied' (or bridging) status. I suggest to get patient or be early and be the first caller with the Immi to penetrate their ellusive customer service hotline lols and get answer with your query.
Pls let me know how you go, my visitor visa also expires end of October but the only edge I have over you is that we've already lodged the PR application
Goodluck to you!