Pit Boss Troubleshooting

Pit Boss 850 Auger Jam: How to Clear It Safely

An auger jam on an 850-series Pit Boss usually announces itself mid-cook: the temperature slides, the hopper still looks full, and nothing is arriving in the firepot. The repair is straightforward, but the order matters — running prime cycles against a solid jam is the fastest way to turn a cleaning job into an auger motor replacement.

Quick Answer

Common causes include pellets bridging over the auger opening, compacted sawdust and fines in the hopper base, moisture-swollen pellets in the auger tube, a foreign object such as a bag tie or wood chip, and a worn auger motor. Check first whether the auger shaft turns at all — that distinguishes a mechanical jam from a motor or wiring failure.

Which symptom matches yours?

  • Temperature drops mid-cook while the hopper is still full
  • The motor hums but nothing moves
  • Pellets in the hopper have swelled, crumbled or turned to dust
  • A cone-shaped void sits above the auger opening
  • Rattling or grinding from the hopper end
  • The problem followed rain or a long spell of humid weather

Diagnostic decision tree

Hum, no rotation

→Mechanical jam — empty the hopper and clear the tube before anything else.

Rotation, no delivery

→Bridging or an empty tube needing a prime.

Silence

→Power, wiring connector or a failed motor.

Grinding or rattling

→Foreign object in the tube or a worn gearbox.

Recurs every few cooks

→Fines and moisture management, not a mechanical fault.

Fixes, easiest first

1. Break a hopper bridge

AddressesPellets arching over the auger so the screw turns in an empty pocket.

  1. Unplug the grill.
  2. Look for a cone-shaped void directly above the auger opening.
  3. Break the arch with a wooden spoon or gloved hand and stir the hopper.
  4. Top up with fresh pellets so the load settles evenly.

Expected resultFeeding resumes on the next prime.

When to stopRepeated bridging means the pellets are damp or dusty — replace them.

Never reach into a hopper with the grill plugged in.

2. Empty the hopper and clear the auger tube

AddressesCompacted fines, swollen pellets or a foreign object.

  1. Unplug the grill and let it cool fully.
  2. Use the hopper clean-out door if fitted; otherwise scoop the pellets out.
  3. Vacuum all sawdust and fines from the hopper floor and around the auger opening.
  4. Inspect the exposed auger flights for wood chips, bag ties or screws and remove anything foreign.
  5. If the screw remains locked, follow the Pit Boss manual's auger service procedure rather than forcing it.

Expected resultA screw that turns freely under power.

When to stopDo not lever or hammer the auger, and do not run repeated prime cycles against a solid jam.

3. Prime and verify feeding

AddressesAn emptied auger tube after clearing a jam.

  1. Refill with fresh, dry pellets.
  2. Clean the firepot so it starts bare.
  3. Run the prime routine until pellets fall into the firepot.
  4. Clear the primed pellets before a normal start-up.

Expected resultSteady pellet delivery.

When to stopNo delivery with a clear tube points to the motor.

4. Diagnose the auger motor and wiring

AddressesA motor that hums, stalls or does nothing.

  1. With the tube clear, run a prime and listen at the hopper end.
  2. Check the motor's wiring connector for corrosion, moisture or a loose plug — outdoor grills lose connections to damp before they lose motors.
  3. A hum with no rotation, a hot housing, or a burning smell indicates a failed motor.
  4. Fit the correct Pit Boss auger motor for your 850-series model or arrange service.

Expected resultContinuous smooth rotation under load.

When to stopStop immediately if the motor is hot or smells of burning insulation.

Unplug the grill before touching wiring.

5. Prevent recurrence

AddressesThe moisture-and-fines cycle behind most jams.

  1. Empty the hopper when the grill will sit unused, especially outdoors.
  2. Store pellets sealed and indoors, off concrete.
  3. Vacuum hopper fines at every pellet change.
  4. Use a fitted cover so rain cannot track into the hopper lid seam.

Expected resultStable feeding and fewer mid-cook temperature drops.

When to stopFrequent jams with clean, dry pellets suggest a worn auger or gearbox.

Pit Boss 850 / Navigator 850: what makes this model different

Feed system
Single auger screw driven by a geared motor from a side hopper
Service access
Many 850-series Pit Boss hoppers include a clean-out door, which makes emptying for a jam far quicker than scooping
Failure signature
Falling temperature with a full hopper; the controller reports temperature, not the jam
Main cause
Moisture-swollen pellets and accumulated fines compacting in the auger tube
Service parts
Auger motor, auger screw, hopper wiring harness

When to stop troubleshooting

  • The auger motor is hot, smells of burning insulation, or trips the circuit — unplug and stop.
  • The screw will not turn after the hopper is empty and the tube is clear.
  • Wiring is corroded, chewed or has melted insulation.
  • Water has pooled in the hopper or reached the control housing.
  • You see flame or smoke coming from the hopper at any point — shut the grill down and do not restart it.

Sources and references

Procedures are summarised from the sources above and from the owner's manual for this model. Always follow the manual supplied with your grill where it differs.

More Pit Boss troubleshooting

Related GrillWizardOz content

Common Questions

Frequently Asked Questions

Why does the Pit Boss hopper clean-out door matter for a jam?
It lets you dump the pellet load in seconds rather than scooping a full hopper by hand, which is what makes clearing the tube and vacuuming fines practical enough to do regularly rather than only after a failure.
Can I clear a jam by running the auger back and forth?
No. The auger drives in one direction and repeatedly loading it against a solid obstruction is the most common way owners burn out a motor. Empty the hopper and clear the tube physically first.
Do cheap pellets really cause jams?
Low-grade pellets tend to arrive with more fines and break down more readily, and both effects compact in the auger tube. Dryness matters even more than brand — pellets that have absorbed moisture swell and disintegrate.