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I'll second fla-tan's welcome. This is a great board with lots of helpful folks.
I'm not sure if you can consolidate if you only have one FFEL loan, but you should call and ask. You may consolidate a single loan, however, most servicers have a minimum loan amount for consolidation. Direct Loans does not have a minimum. For people that have, and expect to continue to have, severe income difficuties, Direct Loans is an excellant option. I know Direct Loans and Sallie Mae will let you - never dealt with ACS. I also don't know the particulars about your loan, but even if ACS doesn't offer FFEL consolidation for one loan, you may be able to consolidate with someone else. I think there's a sticky on this board with links to consolidators.
I would definitely not advise anyone to consolidate a loan with their spouse. If something happens to one spouse, the other is responsible for the entire payment. Cheech this is no longer correct. If a spouse dies or becomes permanently disabled, their portion of the spousal consolidation is now forgiven. There still are potential negatives with a spousal consolidation, but death and disability on no longer on that list.
If you can't consolidate his loan, what about getting on an income-sensitive or graduated repayment plan? Is he in a field where he could possibly get the loans reduced (like a teacher)? Is he permanently disabled?
I've been down this road - maxed out my forbearance and deferment, kept racking up interest, and finally defaulted. I just got through rehab last year. It's a tough situation to be in, and one I wouldn't wish on anyone else. Student loans don't go away, so unless you rework your budget or bring in more income, reducing your payments somehow so you can keep them current is probably the best way to go.
It's hard to give specific advice since I don't know any particular information about your loan, but at least maybe this will help you figure out some options.
fla-tan