This guide walks you through replacing the hopper assembly on Traeger grills. It includes the tools you'll need, relevant SKUs, and an estimated time of about 40 minutes to complete. The steps cover preparation, removing panels and wires, unscrewing the hopper, swapping out wiring harnesses, installing the new hopper, reconnecting wires, and running a self-test before putting everything back together. Having a second person to help is recommended.
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Applicable SKUs
| Grill | Replacement Part SKU |
| Ironwood | 120V: KIT1114 | 230V: KIT1118 |
| Ironwood XL | 120V: KIT1113 | 230V: KIT1117 |
| Timberline | 120V: KIT1112 | 230V: KIT1116 |
| Timberline XL | 120V: KIT1111 | 230V: KIT1115 |
Tools Needed
- Phillips screwdriver
- Optional: Impact driver
Before removing the hopper service panel: check your grill’s manufacturer date.
- June 2023 (2306) or after: Proceed to remove service panel.
- Before June 2023 (2305): Remove the access panel using an impact driver to prevent the possibility of stripped screws. If you don't have one on-hand, contact Traeger Support.
Estimated Time to Complete
Approximately 40 min
Pro Tip: Replacing a hopper assembly is easier when done with two people.
How to Replace a Hopper Assembly
Prepare the Grill
- Turn off and unplug the grill.
- Empty the hopper.
- Check for stripping screws.
Step 1: Remove Hopper Access Panel & Thermocouple Wire Cover
- Remove 6 screws from the right side of the hopper to take off the access panel.
- Remove 4 screws to detach the Smart Combustion Cover (motherboard cover).
- Remove 2 screws to detach the thermocouple wire cover — this is on the backside of the grill, between the hopper and the lid.
Thermocouple Variations: Some early models may have a thermocouple wire cover with only 1 screw, as seen here:
Step 2: Disconnect Wires from Motherboard & Grill
- Disconnect the thermocouple, ignitor, fan, and Smart Combustion connectors from the motherboard.
Then disconnect the lid sensor from the Smart comb harness, and if applicable, disconnect the induction cooktop from the power strip in the back of the grill.
- Feed the pronged end of the thermocouple wire through the hole left by the wire cover.
Step 3: Unscrew Front P.A.L. Rail Bolts & Remove Hopper
- Remove the 2 bolts and 1 washer that attach the front P.A.L Rail to the hopper assembly. (The rail stays on the grill — removing the hardware allows you to remove the hopper assembly).
- Remove the 6 hopper screws: 4 connecting to the barrel, 2 connecting to the cabinet.
- Loosen and arrange all disconnected wires so they won't catch when removing the hopper assembly.
- Lift the hopper slightly and pull it away from the grill, carefully guiding the wires through the entry points at the bottom of the assembly.
Step 4: Replace Wiring Harnesses
- Remove 2 screws to detach the panel that has the Smart Combustion harness, AC Ignitor harness, and fan wire harness coming through 2 grommets.
This provides access to the space under the barrel. - Replace the AC ignitor harness and Smart Comb. harnesses with the new ones that came with the hopper assembly.
- Reinstall the panel, feeding the harnesses through the correct grommet holes on the panel (Left Grommet: Smart Comb + Fan; Right Grommet: AC Ignitor).
If the grill's original Smart Combustion harness includes a grease sensor:
Some early manufactured grills have a Smart Combustion harness that includes an unused grease sensor connection that extends through the bottom of the grill over to the grease drain and is zip-tied in place.
You'll need to cut the zip tie to remove this part of the harness. Access the zip tie by removing the grease & ash keg and removing the small panel underneath the barrel by the grease drain. Reinstall the panel after cutting the zip tie. The new Smart Comb. harness will not have a grease sensor connection.
Helpful Tips:
- New Hopper Assemblies come with all wires already connected to the Motherboard.
- Wire bundles are ziptied inside the hopper for easy installation.
- The Smart Comb and AC Ignitor wires are attached and grouped in the hopper assembly.
- Other wires are installed and ready to use.
Step 5. Install New Hopper Assembly & Reconnect Wires
- With one person holding the new hopper in position over the grill frame, have the second person route the Smart Combustion, ignitor, and fan wires through their entry points. Set the hopper in place, making sure wires aren't getting pinched anywhere.
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Feed the thermocouple through the new hopper assembly. Connect the thermocouple and all 3 wire harnesses (flame sensor, fan, ignitor) to the motherboard.
AC Ignitor harness connection Fan harness connection Smart Comb harness connection - Run a Self-Test before screwing everything down: MENU > MAINTENANCE & CARE > SELF-TEST. If it passes with no errors, proceed. If errors appear, check the Smart Comb, fan, and AC Ignitor connections before tightening anything.
- Slide the hopper into place, ensuring the auger enters the auger tube.
- Secure with the 6 hopper screws (4 to barrel, 2 to cabinet).
- Reinstall the Smart Combustion cover.
- Reinstall the hopper access panel.
- Reconnect the P.A.L. Rail.