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I was running the USPS methods version 2.8d1. Yesterday I discovered that I could no longer select the displayed parcel post rate (rate was correct.) So today I downloaded and installed 2.9.2a1 (I use insurance) on my test website and everything worked flawlessly. So tonight I made the same changes on my live website. Now the parcel post is being returned and it is higher than priority mail. I ran a compare on the files installed on my test website versus the ones on the live website and they are identical.

I am at a loss as to what to do next, any ideas?

I found the problem, part of the comparison was missing in the usps.php file at line 92. So anytime the weight was less than 6 ounces regardless of the number of pounds, the machinable paramater was set to false.

The lastest version with all of the insurance code has the right line of code.