For the last question, pause keypassing and alt tab to the dead char and run him back manually, or stay dead being useless until your entire team dies or you're res'd :p

As for switching mains, it takes complicated macros with the nodead modifier included; I don't do macros so you'll have to search for it in the macro forum or let someone else answer that :p But it would basically be a macro on all alts set to diff keys that sets a diff toon to Focus, or in a more recent discovery, 1 macro to target each toon in order and set focus to the last targeted one using nodead modifiers, so that if the last toon targeted is dead, it doesn't target him and focuses on the next to last instead. Fairly recent post in the macros forum I think, unsure of post name lol

As for solving the Same Movement keys, either pause keypassing, use Autorun, or mouse-drive(hold down left + right click to move and steer without pressing any keys)