What happened
During the liftoff phase of flight, the first officer, acting as the flying pilot, detected a right wing heavy condition accompanied by difficulties with roll control. In response to the flight control issues, the crew performed a fuel dump and returned to the airport for a landing.
The investigation
Following the landing, a post-flight inspection revealed that three of the five spoilers located on top of the right wing were fully deployed. Upon further examination, mechanics discovered a general-purpose shop rag lodged within the spoiler control pulley system, which had jammed the components in the deployed position.
The investigation focused on the area where the rag was found, which is an open and unprotected section of the center body landing gear wheel well. While the center gear doors are typically closed while the aircraft is on the ground, they can be opened by maintenance personnel to access this area. This specific area is also where the center landing gear retracts forward during normal flight operations.
Records indicated that maintenance had been performed in this area two days prior to the incident. A contract fuel systems repair company had opened several lines in the wheel well to check for leaks. During that maintenance, mechanics were unable to locate any discarded rags, prompting a supervisor to bring rags from another hangar. The supervisor stated he provided diaper-style rags rather than shop-style rags, noting his company preferred them for their higher absorbency. In contrast, a mechanic for the carrier noted that they typically used colored general-purpose shop towels or occasionally white terrycloth towels. The aircraft had completed nine flights through various line stations before the incident occurred. It was noted that during standard walk-around inspections, mechanics do not normally open the wheel well doors to inspect the spoiler pulley system.