Can you one more time download the USPS January 2, 2011 C from post #26 on this thread:
http://www.zen-cart.com/forum/showthread.php?t=171314
Go to Modules ... Shipping ... and do a REMOVE ...
Then, delete the file, on the server, for:
/includes/modules/shipping/usps.php
next, load the USPS January 2, 2011 C copy and then do:
INSTALL
and reconfigure for the USPS shipping module ...
The symptoms you are describing are very similar to a problem with an older version ...


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