UPS MODULE -- Ship rates are inconsistent? HELP?

[aly22]

I'm running zen cart 1.3.8 and using the default UPS shipping module. Settings are below.

In a client's store we have recently added a package that is not calculating correctly at all. The displayed rates are CONSIDERABLY LOWER than my client's ACTUAL UPS RATES, using matching zip code destinations??

Is there an updated UPS module or some other plugin or coding/tweaking necessary to get this to match ACTUAL UPS charges? I am completely confused and my client is afraid of having to eat the cost of actual shipping.

United Parcel Service

Enable UPS Shipping
True

UPS Pickup Method
CC

UPS Packaging?
CP

Residential Delivery?
RES

Handling Fee
2.00

Tax Class
--none--

Tax Basis
Shipping

Shipping Zone
--none--

Sort order of display.
0

Shipping Methods:
1DA, 2DA, GND

For example, a 15.02 pound package to Oregon zip code 97229

I show (via Zen Cart ship estimator):
United Parcel Service (15.20lbs) (Next Day Air) $120.54
United Parcel Service (15.20lbs) (2nd Day Air) $57.45
United Parcel Service (15.20lbs) (Ground) $16.65

My client gets (via UPS) for a 14 pound version of the above to the same zip code:
ACTUAL UPS CHARGE
UPS ground $29.96
2nd day $82.86
overnight $169.92

And yes, we are both using the store origin zip code.

I'm losing my mind!!!

[Ajeh]

From UPS site ups.com with a 6x6x6 package of 15.20 lbs and a $75.00 value I get:

Time and Cost Summary

Rates By ServiceRates By ServiceService Guaranteed By Total
UPS Next Day Air Early A.M.® 8:30 A.M.,
Thursday
December 4, 2008 155.60 USD*


Days In Transit: 1 Billable Weight:
16.0
UPS Next Day Air® 10:30 A.M.,
Thursday
December 4, 2008 122.82 USD*


Days In Transit: 1 Billable Weight:
16.0
UPS Next Day Air Saver® By End of Day,
Thursday
December 4, 2008 110.63 USD*


Days In Transit: 1 Billable Weight:
16.0
UPS 2nd Day Air® By End of Day,
Friday
December 5, 2008 78.49 USD*


Days In Transit: 2 Billable Weight:
16.0
UPS 3 Day Select® By End of Day,
Monday
December 8, 2008 55.83 USD*


Days In Transit: 3 Billable Weight:
16.0
UPS Ground By End of Day,
Tuesday
December 9, 2008 23.77 USD*


Days In Transit: 4 Billable Weight:
16.0

From Zen Cart v1.3.8 I get:

United Parcel Service (Next Day Air Early AM) $155.60
United Parcel Service (Next Day Air) $122.82
United Parcel Service (Next Day Air Saver) $110.63
United Parcel Service (2nd Day Air) $78.49
United Parcel Service (3 Day Select) $55.83
United Parcel Service (Ground) $23.77

What settings did you client test with at UPS?