Maybe Sayid was being deported back to Iraq and that's why he was on the plane? I'll have to look at a map as I have no idea if Guam is en route to Iraq.
As for Hurley, remember 2 weeks ago when Ben's lawyer (Norton??) said that the autopsy showed that the guy outside the mental institution was killed before Hurley got out so they had no evidence against Hurley. That would free him from jail, but I'm wondering WHO convinced Hurley to go back?
But Hurley ran out of his house and confessed to all those killings that took place when he was with Sayid.
I'm thinking Sun is the one who convinced Kate to go back; she seems to be the only person that Kate would listen to (other than Sayid).
As for Aaron, initially I thought maybe Kate gave him to Claire's mom, but that would make it too easy for somebody to find Aaron. How about this: Kate gave Aaron to Sawyer's girlfriend, the one who's raising Sawyer's daughter. That would keep Aaron hidden.
I stated on the other thread - these people are stupid! None of them asked any questions about going back. Like: will we be able to leave again? will the plane just land on the island or will we have to go through another crash or parachute down or something? And Jack's a DOCTOR - you'd think he of all people would have asked Ben why his face was all bloodied! So frustrating!
As for Ben's face, I think Ben was injured by Desmond when he tried to kill Penny. Hopefully Ben didn't succeed, but I'll bet they don't tell us until the end of the season!
More thoughts later, but I have to get to work.