PROBLEM RESOLVED
Lesson learned, don't let the end user have access to files.
After tearing my hair out all day I finally decide to just check all the other files, I start with UPS.php, guess what, that file had been overwritten with the code for the usps patch.
Called the client up and asked them if they changed that file, they of course say no, I pepper them and eventually they come clean and say "You mean UPS isn't the same as the post office? I thought they were both the same so I changed both"
ARGHHHHHH!!!! Earlier they swore up and down that they hadn't changed ANY files, now I find out they changed two! They not to even change files, ever.
Needless to say I billed overtime and changed the password.
Thanks for all your help.



