Still no joy. I have exhausted all options. Bought the used one from the guy who loaned me his controller. Everything good and flying again.
Come to the conclusion it is either hardware issue on main board or software that can't be corrected because of DJI only allows update thru app which cant connect . Cost me $265 for repair, new battery and used controller on top of purchase price , not to mention countless hours searching threads. Used minimally.
To DJI , NOT GOOD ENOUGH ! If it is a hardware failure, it shouldn't and you need to fix your quality control issues and back up your product ( replace part , no charge, regardless of warranty) If it is software , that's still on you, 100%.
Thanks to all who offered their 2 cents worth, hopefully one or more of the suggestions here helps someone get flying.