Magento – Tracking order popup not working

The reason you are getting that error with the test login is because your real tracking would/should not be accessible via the test login.

After doing some digging I found people suggest the following number for tracking ids that work with the fedex testing information:

1. 123456789012
2. 111111111111
3. 797843158299

The last of which is used multiple times in the official fedex documentation.

I had exactly the same problem and it seems that there is solution without extending the API!

The shipment API has an undocumented function called sendInfo. Thanks to [cameronhimself][1] for pointing this.

public function sendInfo($shipmentIncrementId, $comment = '')

So you need something like this (for SOAP V1)

try { 
        $orderIncrementId = "Your ORDER ID";
        $itemarray = array('3' => '3', '4' => '5'); //your order items id's and qty to ship
        $comments = "some optional comments";
        $email = FALSE; //this is important! You do NOT want to sent the shipping email (email is sent with tracking number later)
        $includeComments = TRUE; //if you want to sent the comments with the email to customer

        $shipment = array($orderIncrementId, $itemarray, $comments, $email, $includeComments);

        $nship = $proxy->call($sessionId, 'sales_order_shipment.create', $shipment); //create the shippment. $nship is the new shipment id

        $proxy->call($sessionId, 'sales_order_shipment.addTrack', array('shipmentIncrementId' => $nship, 'carrier' => 'custom', 'title' => 'CARRIER TITLE', 'trackNumber' => 'YOURTARCKINGNUMBER')); //add the tracking number to shippment

        $proxy->call($sessionId, 'sales_order_shipment.sendInfo', array('shipmentIncrementId' => $nship)); //this is the fun part. Send the email of the shippment WITH the tracking number

    } catch (Exception $e) { 
        echo 'Shipment creation failed on order '. $orderIncrementId . ': ', $e->getMessage(); 
    }