Pit Boss Grill Pulled Pork Recipe: Hickory-Kissed Fall-Off-The-Bone Meat

This recipe brings back memories of my first hickory smoke at a family cookout. The slow-smoked pork shoulder transforms into fall-off-the-bone perfection on my Pit Boss grill.

With a simple rub and 8 hours of low heat, the meat absorbs that signature wood-fired flavor. Serve on buns with tangy sauce for a meal that tastes like tradition.

Ingredients for Pit Boss Grill Pulled Pork

Nothing exotic here—just good stuff for slow-smoked pork that tastes like tradition.

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The pork shoulder is what makes this. Bone-in gives you that fall-off-the-bone texture, and Pit Boss grills handle the 8-hour smoke perfectly. Look for shoulders with good marbling at Costco or your local butcher. Hickory pellets are a must—Traeger or Pit Boss brand both work great. Don’t skimp on the wood quality; cheap pellets can leave a bitter taste.

No hickory pellets? Apple or cherry wood gives a sweeter smoke. Swap the brown sugar for honey or maple syrup if that’s what you’ve got. The rub can handle substitutions too—cayenne for heat or cumin for earthiness. For the vinegar spray, white vinegar in a pinch, but cider vinegar adds that classic tang.

Leftovers keep 4-5 days in the fridge, freezes for 3 months. I always make extra—pulls apart even better after a night in the fridge. (worth the extra minute)

Step-by-Step Instructions for Hickory-Smoked Pulled Pork

This method delivers tender, smoky perfection with minimal effort on your Pit Boss grill.

Step 1: Prepare the Pork Shoulder and Rub

Pat the 4 lb Pork Shoulder dry with paper towels to ensure the rub adheres properly. In a bowl, mix 0.5 cup Brown Sugar, 2 tbsp Paprika, 1 tbsp Garlic Powder, 1 tbsp Onion Powder, 1 tbsp Salt, 1 tbsp Black Pepper, and 1 tsp Chili Powder until fully combined.

Add the 2 tbsp Yellow Mustard to the pork shoulder and spread it evenly over all sides—this acts as a binder for the rub. Coat the meat thoroughly with the spice mixture, pressing it into the surface to create a flavorful crust. Let it sit at room temperature for 30 minutes while you prepare the grill.

Step 2: Set Up the Pit Boss Grill for Smoking

Fill the Pit Boss hopper with the 2 cups Hickory Wood Pellets and preheat the grill to 225°F using the smoke setting. Once the grill reaches temperature and produces a steady stream of thin blue smoke, you’re ready to start cooking.

Place the pork shoulder directly on the grill grates, fat-side up. This position allows the fat to render down and baste the meat as it cooks. Close the lid and resist the urge to open it for at least 1 hour—consistent temperature is key for low-and-slow smoking.

Step 3: Smoke and Spritz for Moisture

Smoke the pork shoulder undisturbed for 4-5 hours, maintaining a steady 225°F. After the first hour, begin spritzing the meat every 45-60 minutes with the 0.5 cup Apple Cider Vinegar mixed with an equal amount of water in a spray bottle. This keeps the surface moist and enhances flavor development.

You’ll notice the pork developing a dark, flavorful bark—this is the sign of a good smoke. The internal temperature should reach about 165-170°F at this stage, signaling it’s time for the next phase.

Step 4: Wrap and Continue Cooking

Once the pork reaches 165-170°F internally, transfer it to a large sheet of heavy-duty aluminum foil. Wrap it tightly, adding a splash of the apple cider vinegar mixture before sealing. Return the wrapped pork to the grill and continue cooking until the internal temperature reaches 203°F.

This wrapping step, often called the “Texas crutch,” helps power through the stall while keeping the meat moist. The total cook time will typically be 8-10 hours, depending on your grill’s consistency and the pork’s size.

Step 5: Rest, Shred, and Serve

Remove the pork from the grill and let it rest, still wrapped, in a cooler or warm oven for at least 1 hour. This resting period allows the juices to redistribute throughout the meat, ensuring maximum tenderness.

Unwrap the pork and shred it using two forks or meat claws, discarding any large fat chunks. Mix in 2 cups Barbecue Sauce to your desired consistency—start with half and add more as needed. Serve the pulled pork on 8 whole Hamburger Buns for the perfect sandwich, with extra sauce on the side.

Make-Ahead Tips for This Dish

Prep the Night Before

I always mix my rub the evening before—brown sugar, paprika, and spices blend better overnight. Store it in a mason jar to keep it fresh. This saves 10 minutes the next morning when you’re ready to coat the pork.

Early Morning Start

Set your Pit Boss to 225°F first thing. While it heats, pat the 4 lb pork shoulder dry and apply the rub. The 30-minute rest for the meat gives you time to prep your spritz bottle with apple cider vinegar.

Overnight Rest

After smoking, wrap the pork in foil and let it rest in a cooler for up to 4 hours. This works great for afternoon gatherings. The meat stays hot and absorbs all those smoky flavors.

Freeze for Later

Portion shredded pork into quart-sized freezer bags with some juices. It freezes beautifully for up to 3 months. I label mine with the date and Pit Boss notes for reference. ❄️

Reheating Tips

Thaw overnight in the fridge, then reheat in a slow cooker on low with extra barbecue sauce for 2-3 hours. Add a splash of apple cider vinegar to brighten flavors before serving.

Pro Tip

Make extra rub and store it in an airtight container. It keeps for 2 months and works on chicken or ribs too. I always have some on hand for spontaneous cookouts. 💡

Frequently Asked Questions