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Ford Explorer Community - Maintenance - Modifications - Performance Upgrades - Problem Solving - Off-Road - Street
Explorer Forum Covers the Explorer ST, Explorer Sport, Explorer Sport Trac, Lincoln Aviator, Mercury Mountaineer, Mazda Navajo, Ford Ranger, Mazda Pickups, and the Ford Aerostar
The only way it would fall out is if something like what happened to me happened. If the previous owner replaced the modulator valve and lost that pin in the process, as I did, without knowing it. Its a small pin and easy to miss/fall out when you jerk the old valve off. I don't think there's any way it'd break, it's just a small steel pin.
Edit: Yeah, I just looked in my Haynes manual. They call it a vacuum diaphragm and it's pretty much right in the middle of the tranny housing from front to rear and top to bottom with a vacuum hose/hookup going into it facing the rear of the truck. It's got a heat shield you gotta take off (says carefully pry off) to get to it, then a retaining clamp and bolt to take off to take it out. The bolt for the clamp is on top of the valve and I remember it was much easier taking out through the tranny hump inside the truck as apposed to from underneath. It's kind of a pain to get to, but you sound like you've already did worse so far, heh. It would definitely be a cheap fix/easy if this was it though. Good luck.