The best way to ensure your pellet grill lasts for years to come is to purchase one that's built well and features quality construction. If you're in the store, lift the lid and feel its weight—is it flimsy or made from a heavier gauge steel? Pellet grills aren't like offset smokers, they don't need to be hefty, but they shouldn't feel delicate either. When you close the lid, see how it lays on the grill—are there gaps or is it flush, providing a good seal? Check out the joints, the hardware, and any welding—does the grill feel solid? It should be sturdy and all the joints and seams should fit together snugly, no gaps or spaces for heat to escape.
Bought a Traeger Timberline 850. A lot of money but it's a great smoker. It has WiFire so you can cook based on their recipes right from your iPhone. The problem is with their recipes that aren't built into their app. Nobody proofreads the things so many of them are useless. Just one example - Santa Maria Tri-Tip: smoke for 4-5 hours. At what temperature? 165 F, 250 F, or 500 F? It makes a bit of a difference ! I suspect they pay people to write, and post recipes so the can say they have thousands of (what are actually useless) recipes.
A FOLLOW UP: Traeger has agreed to send me replacement parts for the defective ones and I don't have to return them. However I am not returning the grill. I tried to cook a prime rib and a Boston butt. The grill randomly turned off three times and it had the "mini-explosion" others have talked about where the unit actually has an explosion within the housing lifting off the lid a couple inches and making a loud boom. This is not only a potential safety issue, but the "set and forget" is simply not true. It turned off within an hour after setting the temperature at 225 and leaving it unattended for an hour. This is not what I expected or wanted. Sorry Traeger quality is not what it is cranked up to be and certainly not worth the premium pricing they charge for their name. DON'T BUY THIS IF YOU EXPECT TO GET A GRILL THAT WORKS AS ADVERTIZED.

I spent a lot of time researching smokers before committing to the 640. I wanted something that can basically be left alone, produce good results and be durable. The 640 meets and exceeds those goals. It is built like a tank, and weighs about as much. I needed two people to help me assemble and move it. Assembly was straiightforward and took about 90 minutes. I have about 4 cooks on it and cannot be happier with the results.
Never worry about overcooking or burning your food. Masterful control of airflow throughout all chambers allows you to skillfully prepare food with savory natural hardwood flavor. Our propriety exhaust system makes for even grilling and smoking in the main grilling chamber, and sliding damper vents allow great versatility and control when using the upper and lower smoke cabinets. The fan-forced convection airflow in the main barrel allows the grill to work like a convection oven with indirect flame cooking, while the sliding plate on the flame broiler gives the option to sear a steak using direct flame cooking when desired. The removable upper cooking racks in the main barrel adds additional cooking space: cook dinner on the bottom and prepare vegetables and dessert at the same time on the top racks.

With 440 square inches of cooking space, an auger-fed pellet delivery system, and a digital LED thermostat and controller, your cooking will be simple, whether it’s burgers, a whole turkey, or racks of ribs. The side shelf is a convenient place for cooking tools or plates while the bottom shelf can hold spare bags of pellets or jugs of sauces out of the way.

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