If he can go into boot recovery won't the PD15IMG.zip file work? Just a thought.
I actually tried that, and every step failed. Boot, bootloader, system, etc. It would look like it's flashing the radio and then get stuck at the very end. So I figured maybe a batter pull would completely brick it at that point? Nope... even tried doing a battery pull half way through all the steps that were failing, didn't work. I can still get into hboot and see that S-OFF and get into recovery. Can't do much else.
@faux123 - it was actually very easy to get t-mobile to send me another replacement. I, immediately after calling, got on the line with the tech support guy who sent me over to "advanced tech support" to do a master reset. I told her what was going on and that I already did a "master reset" and it was still having that problem. She didn't even question anything and put in the order for a new phone. I'm just a little nervous sending the other one back but you're right, the insurance deductible or restocking fee is a lot better than paying full price.
Also, I just checked the eMMC on the replacement I have and it has the good chip, so I better not have any more problems with this phone! And I'm going to make sure I put the eng. bootloader on this time lol =)
Thank you everyone for your help! Especially @lanternslight456 for spending a ridiculous amount of time with me trying to help get my phone to work!