Quote Originally Posted by j0ney3 View Post
Ok, looks like I'm talking to myself here but I'll lay it out for others who may be having this same odd issue. Here's what I've got so far:

I updated the SHIPPING_MAX_WEIGHT to "150" (lbs in my case), which is the cutoff for Fedex Ground. Now, it's returning Ground availability on my packages EVEN WHEN THEY'RE SPLIT UP--but only for SOME zipcodes...insanity. I'm going to keep digging
UPDATE: Ok, it has nothing to do with the zipcodes. Fedex Home Delivery, which is chosen by default when there is no "Company" specified, has a maximum weight of 70lbs. So, it appears that the bug is 70+lbs and no "Company" will yield an empty Ground return...I'm going to look into includes/modules/shipping/fedexground.php and see where it's sending the request, perhaps there is a "service type" component that needs to be automatically switched to "Ground" instead of "Home Delivery" based on the weight of the packages. I'll keep everyone posted