... and as I research some more, it seems like the country code is incorrect, and for some reason comes up as a number 98 instead of US..
$order->delivery['country']['iso_code_2'] outputs the number 98
here's a log of what is sent:
------------------------------------------
DATE AND TIME: 2008-08-14 17:36:28
UPS URL: [url="https://wwwcie.ups.com:443/ups.app/xml/Rate"]https://wwwcie.ups.com:443/ups.app/xml/Rate[/url]
UPS REQUEST: <?xml version="1.0"?>
<AccessRequest xml:lang="en-US">
<AccessLicenseNumber>REMOVED</AccessLicenseNumber>
<UserId>REMOVED</UserId>
<Password>REMOVED</Password>
</AccessRequest>
<?xml version="1.0"?>
<RatingServiceSelectionRequest xml:lang="en-US">
<Request>
<TransactionReference>
<CustomerContext>Rating and Service</CustomerContext>
<XpciVersion>1.0001</XpciVersion>
</TransactionReference>
<RequestAction>Rate</RequestAction>
<RequestOption>shop</RequestOption>
</Request>
<PickupType>
<Code>03</Code>
</PickupType>
<Shipment>
<Shipper>
<Address>
<City>Queen Creek</City>
<StateProvinceCode>AZ</StateProvinceCode>
<CountryCode>US</CountryCode>
<PostalCode>85242</PostalCode>
</Address>
</Shipper>
<ShipTo>
<Address>
<City>Gilberttt</City>
<StateProvinceCode>AZ</StateProvinceCode>
<CountryCode>98</CountryCode>
<PostalCode>85233</PostalCode>
<ResidentialAddressIndicator/>
</Address>
</ShipTo>
<Package>
<PackagingType>
<Code>02</Code>
</PackagingType>
<PackageWeight>
<UnitOfMeasurement>
<Code>LBS</Code>
</UnitOfMeasurement>
<Weight>3.6</Weight>
</PackageWeight>
<PackageServiceOptions>
<InsuredValue>
<CurrencyCode>USD</CurrencyCode>
<MonetaryValue>51.00</MonetaryValue>
</InsuredValue>
</PackageServiceOptions>
</Package>
</Shipment>
<CustomerClassification>
<Code>01</Code>
</CustomerClassification>
</RatingServiceSelectionRequest>