shpping information / free shipper

Hi,
I have had our cart up and running for almost a year. I've just upgraded to the newest version and have found 2 problems.
The first is that in step 1 of check out, when a customer clicks on the "change your address" button, enters a new adress then tries to continue, the shipping rate option (only 1 - percentage) is gone and the cart will not advance past step one. If they go back to using their original address, it advances correctly.
The second problem is the free shipper module. Our shipping is based on % with a minimum shiping amount. There are a few items marked "always free shipping". The icon shows in the product listing, but when the product is added to the shopping cart, shipping is addedas % on the item. I do have the free shipper module installed, and my shipping/packing free shippng 0 weight status option is set to 0.
I usually scower the posts for answers and almost always find them, but haven't been able to solve these problems. Any help or point in the right direction would be greatly appriciated!

Thank You!!