Here's the deal....
The old AustPost module, as well as having to contact 2 different servers to obtain a full set of quotes, it also made *another* contact to the servers during the checkout to obtain just the quote that had been selected.
The ozpost module avoids the need to contact the server during checkout by caching the result of the full set of quotes and then retrieving the single/required quote from the session data.
If your session data isn't being stored/retreived properly there isn't going to be a 'method' (or quote) availalbe to use during the checkout.
This is entirely unexpected of course, so the page is just bombing out.
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