That's MRS. McFoxFace to you!
1. When you roll to move, do you have to move that EXACT amount of squares? Or is it at most? So if I roll a 5, do I have to move 5 or 1-5?
You move from one to five. You don't need an exact count to get in a room.
2. Can the players just pass the robot every turn? Wouldn't that be too easy?
They can pass it each turn.
3. Do players have to roll in the end if they are already back in the safe room?
Yes, they must roll until everyone is back in the safe room with the keys to disarm the bomb. They could roll the dog or the guard which would affect their companions.