AN MD11 ON TKOF AT ROTATION DECLARED AN EMER AND DIVERTED DUE TO FULL L AILERON AND RUDDER TRIM REQUIRED TO MAINTAIN HDG CAUSED BY A MAINT RAG LEFT IN THE SPOILER MIXER.

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AT ROTATION; THE PF FO HAD FULL YOKE DEFLECTION TO COUNTERACT FLT CTL FORCES. FULL L AILERON WAS REQUIRED TO MAINTAIN HDG. AFTER CLEAN-UP; IT WAS DECIDED TO DUMP FUEL AND RETURN TO HNL. FLT CTL SYNOPTIC SHOWED NORMAL WITH BOTH FLT SPOILERS BEING UP; WITH FULL L AILERON AND SPOILERS; THE R FLT SPOILERS ALSO SHOWED UP. STICK SHAKER ACTIVATION HAPPENED SEVERAL TIMES; EVEN THOUGH IAS WAS WELL ABOVE THE BOTTOM FOOT. DURING DUMP THE L DUMP VALVE FAILED AND THE AUTOMATIC DUMP COULD NOT KEEP THE FUEL BALANCED NOR ON SCHEDULE. I WAS ASSIGNED TO RUN THE FUEL SYS MANUALLY; KEEPING THE FUEL BALANCED; AND CONTINUING TO DUMP. THE CAPT AND FO CONTINUED TO FLY THE AIRPLANE AND TALK TO MAINT. AFTER DUMPING FUEL; DOING A CTLABILITY CHK AND MUCH BRIEFING OF POSSIBLE SCENARIOS; AN APCH AND LNDG WAS MADE BACK TO HNL. BOEING SUGGESTED DOING A FLAPS 28 DEG LNDG. 185 KIAS WAS USED WITH MAX AUTOBRAKE. AUTOPLT WAS DISCONNECTED BTWN 1000 FT AND 500 FT AGL. 1/2 OF THE RUDDER AND AILERON TRIM WAS REMOVED. (FULL TRIM IN EACH DIRECTION WAS IN USE.) THE CAPT MADE A SUCCESSFUL LNDG AND 2 TIRES BLEW THEIR FUSE PLUGS IN THE GATE. POSTFLT INSPECTION REVEALED THAT THE L DUMP VALVE HAD INDEED FAILED AND THAT FOD IN THE FORM OF A RAG WAS IN THE SPOILER MIXER VALVE CAUSING 3 SPOILERS IN THE R WING TO DEPLOY. PREFLT AND BEFORE TKOF CHK DID NOT REVEAL ANY SPOILER DEPLOYMENT. HOWEVER; ON CONFIGN SYNOPTIC FULL UP SPOILER DEPLOYMENT IS EASY TO IDENT; PARTIAL DEPLOYMENT IS EASY TO MISS. MURPHY'S LAW APPARENTLY IN USE. VENDOR MAINT LEFT RAGS THAT ALMOST CAUSED A MAJOR DISASTER. ACFT HAD FLOWN FLTS PREVIOUS. THIS ALSO WOULD HAVE BEEN A TOUGH PROB WITH 2 PLTS. I AM GLAD I WAS THERE TO HELP. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR SAID THE PROB WITH THE ACFT WAS PARTIAL R WING SPOILER DEPLOYMENT NOT ABLE TO BE SEEN ON THE SYNOPTIC INST PANEL DISPLAY DURING THE PREFLT CHK. THE RPTR STATED THIS ACFT HAD 9 FLTS SINCE A CONTRACT MAINT CHK AND WHEN MAINT OPENED THE MAIN GEAR DOOR; ALL SORTS OF DEBRIS INCLUDING RAGS FELL TO THE GND. THE RPTR STATED IT WAS THEN MAINT FOUND A RED MAINT RAG JAMMED IN THE SPOILER MIXER CAUSING THE PARTIAL DEPLOYMENT OF THE R FLT SPOILERS. THE RPTR SAID NO EMER PROC EXISTS FOR THIS EVENT AND NOTHING IS CALLED OUT FOR THE RELIEF PLT TO ACCOMPLISH. THE RPTR SAID THE CAPT DELEGATED THE DUMPING OF FUEL TO THE RPTR AND THIS WAS A PROB AS ONE FUEL DUMP VALVE FAILED CLOSED. THE RPTR STATED THE FAA HAS STARTED AN INVESTIGATION.