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A series of ZSM-5 zeolites with tunable mesoporosity were synthesized by a facile ultrasound-assisted method. XRD, FT-IR and NH 3 -TPD results exhibited that as-synthesized ZSM-5 kept the MFI structure as well as the original acidity. Traced by TEM techniques, the crystallization process, especially the state of initial amorphous gel, was found notably affected by the ultrasound treatment by breaking the weak bonds, which led to formation of mesopores in crystals. The ZSM-5 catalysts with abundant mesoprores inhibited coking significantly and showed high catalytic stability for methanol to propylene reaction. The Z5-us-60 catalyst exhibited the highest catalytic stability for >600 h at a high WHSV of 4.0 h −1 . [ABSTRACT FROM AUTHOR]