1. Have never seen or heard of a procedure to reverse the process, and don't see how it could be done since it requires the new NVRAM cartridge to do the upgrade.
2. The upgrade tool is just a PCMCIA card that is used with the NVRAM cartridge of the new 2-piece software of 4.x and greater. To do the upgrade you simply power down the KSU with the 1-piece s/w, insert the new NVRAM cartridge with the upgrade tool, and reboot. You will be prompted to insert the new feature card. Power down, change the PCMCIA cards, and power up. Done.
If you are upgrading from s/w greater than 3.0 you don't need the tool