Disability and 401k withdrawal = do I pay the penalty? Can I get the status changed?

My husband suffered a traumatic brain injury last Feb. He has been in rehab for the past year in Colorado & Missouri. In May, we pulled out his 401k to pay off bills due to his not working - although we are receiving work comp, it was too stressful trying to keep up with excess debt. My question is this: On his 1099-R it does not say disability - it reads early withdrawal. Can I go back and get the disability status - since he hasn't worked for a year, and is about to move to Omaha to another rehab for the next 6 months? Although he is better than anyone, especially the doctors, ever expected... they are not optimistic that he will ever hold down a job again. We are also currently getting SSI disability payments that kicked in last December. Please advise! I'm working on our taxes now... and we fell slightly below the 7.5% medical deduction. I had 10% already taken out - not state though. And probably not enough federal... any ideas?