IF it's related to addresses (which could happen if you've mangled the countries or zones or geo_zones or zones_to_geo_zones tables by editing them or mass-importing things or installing plugins that alter them) then perhaps that "not working" UK address could be fixed by going into the customer's My Account area (for your test customer or the real customer) and adding a new address (theoretically identical) and setting it to primary and then deleting the previous bad one.
Just an idea.



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