Fedex Module Error Shipping Method

[Eversale]

seem to get an error. I checkked the php, the same moduel for 2.0.25 and 2.1, so i don't think this is 2.1 related.

Fedex moduel seems to send and fetch the correct live data (see attached jpg), but when i select one of the FEDex options, it pops up a message window 'There was an error setting shipping method, please inform company.com about this error'
p.s I updated the SVn to latest today, inc the recent single-page checkout, and stil have the error.
i also have the same error, whether I sign into a user account first, or use the one-page - stil the same error when you click on a shipping option.

any ideas ?

verbose fedex data here:
Data sent to Fedex for Rating: 0,"25"10,"121486130"498,"6348143"8,"FL"9,"33767"11 7,"US"17,"33767"16,"FL"50,"US"75,"LBS"1116,"I"1401 ,"6.0"1529,"1"1415,"54.95"68,"USD"440,"Y"1273,"01" 1333,"1"99,""
Data returned from Fedex for Rating: 0,"125"1376,"LBS"1377,"LBS"1092,"2"1133,"7"2399-1,"0"1273-1,"01"1274-1,"01"1090-1,"USD"1089-1,"01486"431-1,"N"1402-1,"6.0"1416-1,"28.15"1417-1,"4.59"1418-1,"4.50"1419-1,"28.24"1420-1,"0.00"194-1,"FRI"195-1,"TPA"409-1,"22Oct10"2399-2,"0"1273-2,"01"1274-2,"03"1090-2,"USD"1089-2,"05980"431-2,"N"1402-2,"6.0"1416-2,"12.35"1417-2,"3.53"1418-2,"1.98"1419-2,"13.90"1420-2,"0.00"194-2,"MON"195-2,"TPA"409-2,"25Oct10"2399-3,"0"1273-3,"01"1274-3,"06"1090-3,"USD"1089-3,"00006"431-3,"N"1402-3,"6.0"1416-3,"53.15"1417-3,"6.95"1418-3,"0.00"1419-3,"60.10"1420-3,"0.00"194-3,"FRI"195-3,"TPA"409-3,"22Oct10"2399-4,"0"1273-4,"01"1274-4,"05"1090-4,"USD"1089-4,"01283"431-4,"N"1402-4,"6.0"1416-4,"22.75"1417-4,"4.23"1418-4,"3.64"1419-4,"23.34"1420-4,"0.00"194-4,"FRI"195-4,"TPA"409-4,"22Oct10"2399-5,"0"1273-5,"01"1274-5,"20"1090-5,"USD"1089-5,"07167"431-5,"N"1402-5,"6.0"1416-5,"10.65"1417-5,"3.42"1418-5,"1.70"1419-5,"12.37"1420-5,"0.00"194-5,"TUE"195-5,"TPA"409-5,"26Oct10"2399-6,"0"1273-6,"01"1274-6,"90"1090-6,"USD"431-6,"N"1402-6,"6.0"1416-6,"5.53"1417-6,"2.64"1418-6,"0.44"1419-6,"7.73"3058-6,"1"1992-6,"0.00"2399-7,"0"1273-7,"01"1274-7,"92"1090-7,"USD"431-7,"N"1402-7,"6.0"1416-7,"5.53"1417-7,"2.96"1418-7,"0.44"1419-7,"8.05"3058-7,"1"1992-7,"0.00"99,""