Pulled Pork Gas Grill Recipe: Slow-Smoked Tenderness With Caramelized Bark

This gas grill method delivers tender pulled pork with a caramelized bark that rivals traditional smokers. After years of competition cooking, I’ve perfected the technique for consistent results at home.

Low and slow heat transforms the pork shoulder into melt-in-your-mouth perfection. The rub creates a flavorful crust while the meat stays juicy inside.

Ingredients for Pulled Pork Gas Grill

Pork shoulder and a bold rub transform into tender perfection on your gas grill.

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The pork shoulder is non-negotiable here. Bone-in yields superior flavor and moisture, so seek out a well-marbled cut from Whole Foods or your local butcher. Avoid pre-ground or lean cuts—they won’t stand up to the long cook time. For the rub, freshly ground spices make a noticeable difference, so check the expiration dates on your jars.

No bone-in shoulder? Boston butt (boneless pork shoulder) works nearly as well. Out of brown sugar? White sugar plus molasses at one-eighth the volume replicates the depth. The barbecue sauce can be store-bought (Stubb’s or Sweet Baby Ray’s are reliable), but for competition-style bark, use a vinegar-based sauce. Apple cider vinegar is irreplaceable—don’t substitute white vinegar.

The rub can be mixed 2 days ahead and stored in an airtight container. Cooked pork stays juicy for 4 days in the fridge or freezes for 3 months—reheat gently with extra sauce to revive the bark.

Step-by-Step Instructions for Pulled Pork on a Gas Grill

Master the technique for fall-apart tender results with a perfect caramelized crust using your grill.

Step 1: Prepare the Pork Shoulder with a Flavorful Rub

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

Rub this mixture evenly over the entire surface of the pork, pressing it in to create a thick crust. Add the 0.25 cup Yellow Mustard to the remaining rub and mix to form a paste. Spread this paste over the pork to act as a binder and enhance the bark formation.

Step 2: Set Up the Gas Grill for Indirect Heat

Preheat your gas grill to 225°F for low and slow cooking. Turn off one set of burners and leave the other side on low to create an indirect heat zone. Place a disposable aluminum pan filled with water on the heat source to maintain moisture and stabilize the temperature.

Add wood chips or pellets (like hickory or apple) to a smoker box or wrap them in foil and poke holes to create smoke. Position the pork shoulder on the grill grates over the indirect heat side, fat side up. Close the lid and maintain the temperature between 225°F and 250°F.

Step 3: Smoke and Monitor the Pork

Smoke the pork undisturbed for 3 to 4 hours. During this time, spritz the pork every 45 minutes with a mixture of 0.5 cup Apple Cider Vinegar and water to keep it moist and enhance the bark. This step is crucial for achieving that coveted caramelized exterior.

Continue smoking until the internal temperature of the pork reaches 165°F to 170°F. At this point, you may notice the temperature stalls as moisture evaporates. Wrap the pork tightly in aluminum foil or butcher paper and return it to the grill to power through the stall.

Step 4: Finish Cooking and Rest

Continue cooking the wrapped pork until the internal temperature reaches 200°F to 205°F. This typically takes an additional 2 to 3 hours. Use a meat thermometer to check for doneness—the pork should be probe-tender, with the thermometer sliding in like butter.

Once done, remove the pork from the grill and let it rest, still wrapped, for at least 1 hour. This resting period allows the juices to redistribute, ensuring the meat stays moist and tender when shredded.

Step 5: Shred and Serve with Barbecue Sauce

Unwrap the pork and transfer it to a large bowl or cutting board. Use two forks or meat claws to shred the pork into bite-sized pieces, discarding any large fat chunks. The meat should pull apart effortlessly, a sign of perfect tenderness.

Toss the shredded pork with 2 cups Barbecue Sauce to coat evenly. Serve immediately on buns, in tacos, or as a standalone dish. The combination of smoky, tender pork and tangy sauce delivers a flavorful experience that highlights your grill mastery.

Storing and Reheating pulled pork gas grill

Refrigerator Storage

Let the pork cool to room temperature, then transfer to airtight containers—I use glass Pyrex with snap-on lids. Store at 40°F or below for up to 4 days. The flavors actually meld and improve overnight, making leftovers taste even better. ❄️

Freezer Storage

For longer storage, freeze shredded pork in quart-sized freezer bags with as much air removed as possible. It stays at peak quality for 3 months. I portion mine into 1 lb bags for easy meal prep later.

Stovetop Reheating

This is my preferred method. Heat the pork in a heavy pot with ¼ cup Barbecue Sauce and 2 tbsp water over medium-low heat for 10-15 minutes. Stir occasionally to prevent sticking. 🔥

Oven Reheating

Spread pork in a baking dish, add ½ cup Barbecue Sauce, and cover with foil. Bake at 300°F for 20-25 minutes, then uncover and bake 5 more minutes to restore the bark.

Microwave Reheating

For quick meals, microwave individual portions with a splash of sauce. Use 50% power for 2-3 minutes, stir, then continue in 30-second bursts until reaching 165°F. Add extra sauce after heating.

Frequently Asked Questions