I have contemplated on how to explain this! Our shipping is just not working right. I have USPS up, all approved with my webtools ID. FedEx the same thing. I have the free shipper turned on. As far as zones, that is the only thing I'm not sure I've done correctly, but it shouldn't matter on what this crazy thing is doing.
Here are the problems}
1. If I put free shipping on a product, and someone adds a product that is not free shipping, it gives free shipping as an option to choose from and USPS disappears and there is only FedEx. Our customers are of course choosing the free shipping.
2. When the free shipping product is chosen only, it shows both free shipping and fedex, no usps.

3. If I turn off the free shipper mod, and leave free product 0 weight, mark shipping as free it charges $1.30 for our magazine which is free shipping or shows again fedex and free shipping as a choice. Sometimes it behaves and shows only the total purchased with the words free shipping in total; and the checkout button.. Which is what I think it should do instead of going to the delivery page with the stupid fedex and free shipping showing!

4. Ok, free shipping is on now again, I put 2 products in the cart with no free shipping and USPS and Fedex come up correctly, then I put a free shipping product in and USPS disappears, fedex and free shipping are the choices again.


It seems to work every now and then... I'll go back in when a customer gets a charge on their free shipping order, try it a few times, it's working then all of a sudden it's not again..

Most of our free shipping products have attributes attached. fyi

But it seems that USPS and free shipping don't mix.. I've removed the USPS and added it back in... still doesn't seem to work right.
I have version 1.37; my site is www.joyoushome.com

Any ideas? Thank you! Theresa