This brown sugar rubbed Pit Boss pulled pork is my go-to for backyard BBQs. After years of testing, I've dialed in the technique - from rub to rest - for fall-apart-tender results every single time.
If you love this recipe, check out my Smoked Pulled Beef from Chuck Roast next!
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Looking for more pulled meat recipes? Try my Traeger Smoked Pork Butt, Traeger Smoked Pulled Pork Loin, BBQ Braised Dutch Oven Pulled Pork, and Juicy Smoked Pulled Chicken.
What Makes This Recipe Work
I've tried dozens of pulled pork recipes over the years, and this one consistently gives me the best results.
Yellow mustard isn't just for hot dogs. It creates a sticky base that holds the rub better than oil. Apply it generously, you won't even taste it.
Wrapping at 165°F takes the guesswork out. I used to wrap based on time or looks, but temperature is way more reliable. Hit 165°F and it's time to wrap.
203°F is the magic number. This is where the tough connective tissue breaks down completely. I've pulled pork at lower temps before, and you can definitely tell the difference.
That hour-long rest makes all the difference. I know it's tempting to dig in right away, but letting it sit wrapped in towels redistributes all those juices back through the meat.
Ingredients for Pit Boss Pulled Pork
- Pork Shoulder (5-8 pounds): This cut is also known as "picnic shoulder" or "picnic roast". It is usually boneless. You can also use a pork butt or "Boston butt" which has more marbling and can be boneless or bone-in. This cut usually contains more marbling.
- Yellow Mustard: Plain old French's yellow mustard works perfectly.
- Pulled Pork Dry Rub: I used a simple blend of my favorite seasonings and spices: Brown sugar, smoked paprika, kosher salt, black pepper, garlic powder, and onion powder
- Peach Butcher Paper or Heavy-Duty Foil: I prefer butcher paper, but foil works fine, too.
How To Make Pit Boss Smoked Pulled Pork
Quick Overview
- Preheat Pit Boss to 225°F.
- Trim and dry pork shoulder; coat with mustard and rub.
- Smoke unwrapped to 165°F.
- Wrap in butcher paper; smoke to 203°F.
- Rest in cooler 1 hour.
- Shred, serve, and enjoy!
Getting Started
Fire Up the Pit Boss: Preheat your pellet grill to 225°F and load it with your favorite pellets.
Prepare the Pork Roast: If you have a fat cap, trim it down to about ¼ inch-enough to keep things moist but not so much that it won't render properly. Pat the whole thing dry, then slather it with yellow mustard using a brush or your hands.
Mix the ingredients for the spice rub and coat every inch of that pork, pressing it in so it sticks. You can also do this the night before and let it sit in the fridge.
Smoking Pit Boss Pulled Pork
First Phase: Place the pork fat side up directly on the grill grates. Insert a temperature probe, close the lid, and leave it alone for the first few hours. The surface gets dark and crusty, which is exactly what you want.
The Stall: Around 160°F, the temperature seems to stop climbing. This happens because moisture evaporating from the surface cools the meat down. It's totally normal, keep cooking.
Time to Wrap: I leave the meat alone until I hit 165°F internal temp. Then I pull it off and wrap it tight in butcher paper. This pushes through the stall and keeps everything moist.
💡 Pro Tip: If you use foil instead of butcher paper, expect a slightly softer bark. Still tasty, just a bit softer.
Back on the Smoker: Place the wrapped pork back on the smoker at 225°F and insert the temperature probes again. Close the lid and smoke it until you reach an internal temperature of 203°F. This usually takes another 4-5 hours, but every piece of meat is different.
The Rest: Wrap the whole thing in clean towels and stick it in a cooler without ice. Set a timer for an hour minimum. I've let it go for 2-3 hours before with great results.
Pulling Time
Unwrap the pork and save every drop of juice that's collected-that's pure flavor right there. Shred the meat with shredding tongs or two forks, or just pull it apart with your hands. The meat should fall apart when you touch it. Serve on buns, sandwiches, or tacos.
Top Wood Pellets for Smoking Pork
My favorite wood pellets for smoked pulled pork are apple, cherry, or hickory. Oak and pecan are also good. And you can also use the Competition blend by Pit Boss or the Signature blend by Traeger.
Tools I Use for Smoked Pulled Pork
These are my must-haves:
- Wireless meat thermometer - I use the ThermoPro TP829. It tracks temps without babysitting the grill.
- Butcher paper - Peach butcher paper lets the bark breathe while holding in moisture.
- Shredding claws - Easier than forks.
Tips That Actually Matter
- Get a decent thermometer. A good probe thermometer is worth every penny. I use this one.
- Every pork shoulder cooks differently. I've had 6-pounders finish in 8 hours and 8-pounders take 12. Plan extra time.
- That dark bark isn't burnt. This is where all the flavor lives.
- Taste before you sauce. Good pulled pork doesn't need to be drowned in sauce.
Variations
- Coffee Rub: Replace 1 tablespoon of brown sugar with finely ground coffee or espresso powder. Sounds weird, but it's really good.
- Spicy Version: Add a teaspoon of cayenne to the rub. Just enough to give it a little kick.
Leftover Storage Tips
Leftover pulled pork keeps in the fridge for about 4 days. I portion it out and add a little of those reserved juices to each container. For reheating, low and slow in a covered dish works best-300°F in the oven.
I also freeze portions in vacuum bags for up to 3 months. Thaws perfectly and tastes just as good.
Serving Suggestions
My favorite sides are creamy Coleslaw with Miracle Whip, Smoked Baked Beans with Bacon, Smoked Cornbread, and my Refrigerator Sweet Dill Pickles. For sandwiches, I use toasted Light and Fluffy Hamburger Buns or Air Buns.
The pulled pork works with pretty much any BBQ sauce you like, but I always taste it plain first. Sometimes it doesn't need anything at all.
And if you're looking for creative ways to use leftovers, this pulled pork is perfect for my Pulled Pork Taquitos Recipe or loaded up on my Loaded Pulled Pork Fries recipe.
Common Mistakes to Avoid When Smoking Pork Shoulder
- Pulling it too early: Pork shoulder needs time to fully break down. Pulling it at 190°F instead of 203°F? You'll end up with chewy chunks instead of juicy shreds.
- Skipping the rest: This might be the #1 mistake I see. Resting for at least an hour (preferably in a cooler) locks in juices.
- Judging doneness by looks: Don't guess. Always go by temperature-get a reliable meat probe and use it.
- Using cheap pellets: Low-quality pellets can leave bitter flavors and can be dusty. Use a trusted brand-I like Pit Boss or Traeger pellets.
Recipe FAQs
Plan for 10-12 hours total, depending on the size of your pork shoulder.
Yes, but foil traps more steam, which softens the bark slightly.
More Smoked Pork Recipes
Here are some more smoked pork recipes readers love:
- Traeger Smoked Pork Butt - Same great results on a different pellet grill
- Pulled Pork Loin on Pellet Grill - Leaner cut, faster cook time, still incredibly tender
- Smoked Pork Loin Roast Recipe - Incredibly juicy
- Apple Smoked Pork Chops - Quick smoking for weeknight dinners
- Pit Boss Pork Chops - Simple and delicious
- Smoked Pork Tenderloin on Pit Boss - Perfect for smaller gatherings
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Printable Recipe
Pit Boss Pulled Pork
Equipment
- Peach butcher paper or heavy-duty aluminum foil (for wrapping)
Ingredients
For the Pork:
- 1 pork shoulder or pork butt (5-8 lbs) (boneless or bone-in)
- ¼ cup yellow mustard
For the Brown Sugar Rub:
- ¼ cup brown sugar
- 2 tablespoons smoked paprika
- 1 tablespoon garlic powder
- 1 tablespoon onion powder
- 1 tablespoon kosher salt
- 1 tablespoon black pepper
Instructions
- Preheat your Pit Boss pellet grill to 225°F. Load the hopper with your choice of apple, cherry, or hickory pellets.
- Trim the fat cap on the pork shoulder to about ¼ inch, if needed. Pat the pork dry with paper towels, then coat all sides evenly with yellow mustard.
- In a small bowl, mix the brown sugar, smoked paprika, garlic powder, onion powder, kosher salt, and black pepper. Apply the rub generously to all sides of the pork, pressing it in so it sticks.
- Place the pork shoulder directly on the grill grates, fat side up. Insert a meat thermometer into the thickest part of the meat, close the lid, and smoke undisturbed until the internal temperature reaches 165°F-this may take 5 to 7 hours, depending on the size of the pork. A stall around 160°F is normal; just keep cooking.
- Once the pork reaches 165°F, remove it from the smoker and wrap it tightly in peach butcher paper or heavy-duty foil. Return the wrapped pork to the grill and continue smoking at 225°F until the internal temperature reaches 203°F-this usually takes another 4 to 5 hours.
- When the pork hits 203°F, remove it from the smoker. Wrap it in a clean towel and place it in a cooler (without ice). Let it rest for at least 1 hour and up to 3 hours.
- After resting, unwrap the pork and transfer it to a large tray. Pour any collected juices over the meat. Shred the pork using meat claws or forks-it should pull apart easily.
- Serve warm on buns, in tacos, or with your favorite BBQ sides. Taste before adding sauce-the meat will be moist, and the flavor from the rub and smoke may be all you need.
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Notes
- If you don't have butcher paper, heavy-duty foil will still give you great results. Butcher paper just helps preserve that bark.
- Apple, cherry, and hickory pellets all work well. Avoid mesquite for this recipe-it can overpower the sweetness of the rub.
- Leftover pulled pork keeps well in the fridge for up to 4 days. Reheat slowly in the oven, covered, at 300°F with a bit of moisture added.
Nutrition
The provided nutrition information is automatically calculated. Accuracy is not guaranteed.
Jeff says
I tried this recipe today.. put my 6# pork butt in my pit boss smoker at 5:45 am at 230*, it is now 5:40 pm and the internal temp is only at 192*….. 9 hrs per recipe ??? NOT !!!!!!!
Jeri Walker says
Hi Jeff, thanks for trying the recipe! Pork shoulders can be unpredictable, which is why I always recommend going by temperature instead of time. I note in the post that some 6-pound roasts can take 12+ hours because of the stall-it sounds like yours just needed a little longer to hit that 203°F sweet spot for shredding. I hope the final result was still worth it! 🙂