Also, check your USPS Shipping Module code:
/includes/modules/shipping/usps.php
There have been changes over the last year on the settings around lines 99-108 These must match exactly:
PHP Code:
$this->intl_types = array('GXG Document' => 'Global Express Guaranteed Document Service',
'GXG Non-Document' => 'Global Express Guaranteed Non-Document Service',
'Express' => 'Global Express Mail (EMS)',
'Priority Lg' => 'Global Priority Mail - Flat-rate Envelope (Large)',
'Priority Sm' => 'Global Priority Mail - Flat-rate Envelope (Small)',
'Priority Var' => 'Global Priority Mail - Variable Weight (Single)',
'Airmail Letter' => 'Airmail Letter Post',
'Airmail Parcel' => 'Airmail Parcel Post',
'Surface Letter' => 'Economy (Surface) Letter Post',
'Surface Post' => 'Economy (Surface) Parcel Post');
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