Zeus Car battery issues?

Hi, we bought a number of the Zeus cars and built them and and they worked great with the mobile app.
We put them away for a few weeks and are now ready to get going with them again but we are having issues. I’m the teacher so I will explain my issue. I have recharged the battery and the 2 LEDs are on, so that should mean full battery. However when I turn it on, the lights stay orange
and will not go to blue and no WiFi is made available. But when I plug in the USB cable to the arduino board the blue light comes on, I can connect with the app, move the car and see the camera images. As soon as I remove the cable the lights go back to orange and the WiFi is gone. Students have others issue with the WiFi not accepting the password and another one seems to not be charging the battery at all.

To better assist you in troubleshooting, please provide a video of the issue if possible.
If you have a multimeter, could you measure the current voltage of the battery?

Link to video:
https://setuo365-my.sharepoint.com/:v:/g/personal/oisin_cawley_setu_ie/ES1XjIGIiSBMvSIxTdmbObQBCMa-egKP6Y8bc5TL--m-lQ?e=7WqpZg

I don’t have a multimeter at the moment.
From my trials it looks like where the battery connects to the Sunfounder shield could be a little temperamental? sometimes if you disconnect and reconnect the battery no charge flows. I have to disconnect and reconnect a couple of times.

BTW, I replaced the car shield board on one of the other student cars and that one is back working now. Similar battery connection issue perhaps?

Thanks

After you replace another expansion board, the problem can be solved, right?
You can replace the battery of the problematic zeus car with another zeus car and see if it can work normally.
This way you can verify whether it is a battery problem or an expansion board problem.

I used the same battery on a different Zeus car and it worked fine, so that points to a 2nd problematic expansion board. It does appear that the battery connection to the expansion boards are a little temperamental. Sometimes I have to disconnect and reconnect the battery carefully a number of times before it powers the car.

Please confirm whether the upload switch on the expansion board is set to the run position (see attached image). If the issue persists, it may be due to a damaged PCB. Please contact our customer service for after-sales support: service@sunfounder.com.

Yes the button is in the Run position.

Please contact at service@sunfounder.com.We will send you a r Shield module.