see if you can catch it with a sheet rock screw of something simular, you have nothing to lose. The worst thing that can happen is you have to pull the VC, you might get lucky and get the rest out.

 

does anyone have pictures how it look like on inside valve cover? can oil separator drop into valve cover or just sits there? can I bypass this oil separator and run an oil capture bottle? or it needs suction from intake manifold?

 

Yes it just sits there.
Technically yes you can by-pass it, you would just run a hose from the valve cover towards the bottom of the truck and vent the crankcase gases to atmosphere and then plug the vacuum port on the intake plenum.
Thats how they used to do it in the old days.
Just remove the valve cover, clean out the oil separator port and put it back together.

 

This was my thought once until I pulled the cover and looked at it. There's a metal baffle that is riveted to the inside of the valve cover, no real access unless you want to grind the rivets off and then figure a way to reattach it. What I've done since then is use a brad point wood drill bit, somewhat smaller than the diameter of the tube and by hand use it like a roto rooter in a drain. I then use a pointy vacuum attachment on a shop vac and suck the broken pieces out.

 

I also did the drill + shop vac. I drilled out less than one radius on either side of the oil separator as to preserve the central rod while relieving the pressure around the perimeter. Then it came out with one light tug with the needle nose pliers.

 

BTW, I learned through experience with some twisting you can remove the entire steel tube - then remove baffle on the work bench. I figured this out because 03's have a restrictor disc in the top that prevents removing the baffle.