Mystery solved! Tonight we went over everything once again. He remembered he had a copy of the blank rollover form from his new 401K. He was able to show me exactly how he had filled it out, which was totally correct (issuing plan account 401K, direct rollover, no Roth included). Then we looked at the portal for his new 401K and saw that when he set it up, he was given two choices for his employee contributions: Roth, or regular (or some such word). He chose Roth. It was an either or choice. Apparently when his distribution check came in, it was just added to what he already had in the Roth with no regards where it had come from. He has emailed the administrator of the new plan and hopefully we can get this resolved soon.
Thank you to everyone who responded!
