[usps shipping] No Shipping option WHEN registered

Hi Q, great cart! i have one issue hopefully you can help. I am using usps shipping module, no zones, and everything works fine as a guest checkout, but when registered for some reason i keep getting "THe no shipping options error". It only happens for US adresses and not overseas. Can you shed some light?

THANKS!

btw, i also am using the auto-choose payment hack. (not shipping)