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

There’s nothing like the rich aroma of hickory-smoked pulled pork coming off a Pit Boss grill. This method transforms tough pork shoulder into tender, flavorful meat with minimal effort.

By maintaining a steady 225°F and using a simple dry rub, you’ll achieve that coveted bark and fall-apart texture. The pellet grill does most of the work while you enjoy the process.

Ingredients for Pit Boss Pellet Grill Pulled Pork

Simple rub, one cut of meat, and hickory pellets are all you need.

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The pork shoulder is the star here. Bone-in gives you that extra-rich flavor and stays juicier during the long cook. I grab mine from Costco—they’ve got big, well-marbled cuts at a good price. Most butcher shops will also have it labeled as pork butt (same thing). Look for 8-10 lbs if you’re feeding a crowd, but 4 lbs is perfect for this recipe.

No hickory pellets? Apple or pecan wood work great too—sweeter profile but still delicious. Out of apple cider vinegar? White vinegar in a pinch (just not as fruity). For the rub, Penzeys spices are my go-to, but store brands are fine. If you don’t have pork broth, chicken broth works—just skip it entirely if you’re in a bind, the meat still turns out great.

Leftovers keep in the fridge for 4-5 days or freeze for up to 3 months. Pull apart and portion before storing—makes weeknight dinners a breeze. The rub can be mixed ahead and stored for 1 month in a cool, dark place.

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

Here’s my tested method that delivers tender, smoky results every single time.

Step 1: Prepare the Dry Rub and Coat the Pork

In a bowl, combine the 0.5 cup brown sugar, 2 tbsp kosher salt, 2 tbsp black pepper, 1 tbsp paprika, 1 tbsp garlic powder, 1 tbsp onion powder, 1 tbsp chili powder, and 1 tsp cumin. Mix until evenly blended—this creates your flavor foundation.

Pat the 4 lb pork shoulder dry with paper towels, then rub it all over with the 0.25 cup yellow mustard. This acts as a binder for the dry rub. Coat the pork completely with the spice mixture, pressing it in so it adheres well. Let it sit at room temperature for 30 minutes while you prep your grill.

Step 2: Set Up the Pit Boss Pellet Grill

Fill your Pit Boss hopper with the 20 lb hickory wood pellets—this wood gives that classic smoky flavor. Preheat the grill to 225°F with the lid closed. Once it reaches temperature, you should see a steady stream of thin blue smoke coming from the exhaust.

Place a disposable aluminum pan filled with the 1 cup pork broth on the grill grates. This adds moisture to the cooking environment and helps prevent the pork from drying out during the long cook. The pan also catches drippings, making cleanup easier.

Step 3: Smoke the Pork Low and Slow

Position the pork shoulder on the grill grates, fat-side up. Close the lid and smoke undisturbed for 6 hours. Resist the urge to peek—every time you open the lid, you lose heat and smoke, which can add 30 minutes or more to your cooking time.

After 6 hours, check the pork’s internal temperature with a meat thermometer. When it hits 160-165°F, it’s time to wrap. Lay out a large piece of heavy-duty foil, place the pork in the center, and pour 0.25 cup of the apple cider vinegar over it. Wrap tightly to create a steamy environment.

Step 4: Finish and Rest for Maximum Tenderness

Return the wrapped pork to the grill and continue cooking until the internal temperature reaches 203°F. This usually takes another 3-4 hours. The pork is done when a probe or fork slides in and out with no resistance—like butter.

Once done, remove the pork from the grill and let it rest in the foil for 1 hour. This resting period allows the juices to redistribute throughout the meat. If you skip this step, you’ll lose all those delicious juices when you pull it apart.

Step 5: Shred and Serve

Unwrap the pork and transfer it to a large cutting board or bowl. Use two forks to shred the meat—it should come apart with almost no effort. Discard any large fat chunks or the bone if your cut included one.

Mix in the remaining 0.25 cup apple cider vinegar from your spritz bottle if you’d like extra tang. Serve the pulled pork on buns with your favorite barbecue sauce, or use it in tacos, nachos, or sandwiches. The smoky hickory flavor shines through in every bite.

Common Mistakes When Making This Dish

Skipping the Rest

I see too many cooks pull their pork straight off the grill and start shredding. Resting for 1 hour in foil is non-negotiable—it lets juices redistribute. Skip this and you’ll have dry meat on your hands.

Peeking Too Often

Every time you open that Pit Boss lid, you lose 25-50°F of heat and precious smoke. I set a timer and resist the urge to check until the 6-hour mark. Trust the process.

Wrong Wood Choice

Hickory is classic, but I’ve seen people use mesquite for pulled pork—it’s just too strong. Stick with hickory, apple, or pecan for that perfect balance. Mesquite can make your meat taste bitter. 🌡️

Insufficient Rub Application

Don’t just sprinkle the rub on—press it into the meat so it forms a crust. I use yellow mustard as a binder to help it adhere. A light coating ensures every bite is flavorful.

Ignoring the Stall

When your pork hits 160-165°F, it stalls as moisture evaporates. Wrapping in foil with apple cider vinegar helps push through this phase. Without this step, you could add 2-3 hours to your cook time.

Over-Trimming Fat

That fat cap protects the meat during the long cook. I leave at least ¼ inch of fat on the pork shoulder. The fat renders down, basting the meat from within and adding moisture.

Frequently Asked Questions