I'm posting this as a help to anyone who might run into this issue:
I was getting the following error whenever a client has an order totaling more than 150LBS. I'm using Fed Ex realtime shipping. I was told by ASPDNSF support that if I upgraded from 7025 to 8012 this issue would be fixed....(upgrade doesn't fix it)
Index was outside the bounds of the array.
Description: An unhandled exception occurred during the execution of the current web request. Please review the stack trace for more information about the error and where it originated in the code.
Exception Details: System.IndexOutOfRangeException: Index was outside the bounds of the array.
Source Error:
Line 407: Dim frmsplit As String() = ShippingMethodIDFormField.Split("|"c)
Line 408: ShippingMethodID = Localization.ParseUSInt(frmsplit(0))
Line 409: ShippingMethod = String.Format("{0}|{1}|{2}", frmsplit(1), frmsplit(2), frmsplit(3))
Line 410: End If
Line 411: End If
Source File: C:\Inetpub\wwwroot\AspDotNetStoreFront\Web\checkou tshipping.aspx.vb Line: 409
This problem was caused by having too many characters in my callforshipping app config. Apparently, there is a character limit in this field, however, it's not noted anywhere and the gui will allow you to type as much as you want without an error when clicking update. I learned this all the hard way ona production site. I hope it helps someone.