RNE no longer valid. Seeking to get it back

You're probably done for a while and will have to wait. In Canada our consulate will do a PR visa in 2 weeks if your docs are correct, don't know about US processes.

Gotta reapply from square one all over AFAIK. The covid excuse will work, as they tend to look dimly on people who let their RNE/CRNM lapse for no valid reason. The 5 year gap may or may not be an issue, don't know. Go try right ?

I faced the same problem as you during covid. Flew down to GRU in month 18 just to get the PP stamped. It's called a VISA RUN in traveller talk. Spent 4 days in a GRU airport hotel drinking Johnny Walker Red and chatting up various stewardesses at happy hour. Fun times.

07/25/24 @cupofjoe.  It may be possible to get the process moving, and if you have someone you can trust, e.g. an in-law, to whom you can give a Power of Attorney to pick the card up for you and send it to you in the United States, it may work, if you're extremely well-organized and don't waste a minute. 

You should arrive in Brazil with ALL of the documents and appropriate apostilles that apply to your particular situation in your possession.  No cutting corners:  you need them all, and the FBI Background Check must be no more than 90 days old.  Keep duplicates, just in case. The list appears here:

https://www.expat.com/forum/viewtopic.php?id=1058676

If you can already choose a Sworn Translator in Brazil and send them scans of the documents before you even come, that will save you time, and time is of the essence.  The day that your feet hit the tarmac in Brazil, or the very next day if you're too tired, you should start your application online on MigranteWeb.  If you don't already have a Sworn Translator working on your docs, get that done ASAP. 

Answer all Polícia Federal questions honestly, of course, but don't feel the need to volunteer information.  One item not to bring up unsolicited is that you and your spouse do not intend to live in Brazil anytime soon.  Some officers may ignore that, but others definitely may not, so it's better not to invite questions.

By any chance, did you obtain your CIE ("RNE") in connection with a VIPER permanent visa prior to November 2017?  If so, have the passport that contains the VIPER with you, and your CIE.  In your place, I would go to the PF office with the visa and the CIE shortly after arriving and ask if you can renew, since existing VIPERs were grandfathered by the 2017 law, and yours may be considered to still be in effect, regardless of the CIE's validity date.  Chances are that they'll tell you that it lapsed with your CIE, but I would think that it was worth a try.