I got this working now. Hope this explanation can help someone else fighting with this :
I had the free shipping method in it’s own shipping zone targeted towards the U.S. I also had a $75.00 requirement. Shipping under $75.00 to a U.S address showed that there was no shipping method available. I had to add in UPS and Fedex shipping methods to this zone in addition to the “Rest of the world” zone.
So basically, I have a zone called “Free Shipping” with the “United States” region selected. Included in this zone are 3 methods (Free Shipping – [Set to order value > $75], USPS, and Fedex) and second zone called “Rest of world” with 2 methods (USPS, Fedex)
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This reply was modified 8 years, 5 months ago by nerdyone05.