What I would try next is create a new Expo project and start comparing all of the config files between the two apps and modifying your app’s config to look more like the new app, while at the same time modifying the new app’s config to look more like your app.
Hopefully at some point you will either fix your app or break the new app. At that point you should have a better idea of what is xausing the problem.
Alternatively, create a new app and copy all the code and assets across. Check if it works.