Paid shipping -> page 2 -> Handling costs NO, Free shipping NO, Billing by weight, Out of range: Apply the highest cost. I have 4 weight ranges set up.
Page 3 -> Minimum order value US$0 Maximum Order value US$60
Free shipping -> page 2 -> Free shipping YES, Billing by price, Out of range: Disable. All zones selected.
Page 3 -> Minimum order US$60 Maximum order set at 0.00 to disable.
With this set up, an order of US$46 is required to pay a shipping charge. If the currency is changed to CAD with no changes in the cart the order now costs CAD$63.68 and gets free shipping.
Localization -> Currencies USD exchange rate 1 CAD exchange rate 1.384437
Perhaps the problem comes from the Free shipping option on page 2?