Unless you are modifing the value of any of the elements of the cluster, LabVIEW shouldn't make a copy of the cluster as it's passed around.
If you are modifing a value, it may, or may not make a copy. If you have LabVIEW 7.1, there's a tool you can use to see where LabVIEW creates copies of data. Open the block diagram and in the tools menu, go down to 'Advanced', then select 'Show Buffer Allocations'. This will place a small black box on the terminals where data is copied.
I generally pass the entire cluster and unbundel the items I need inside the subVI.
Ed

Ed Dickens - Certified LabVIEW Architect
Lockheed Martin Space
Using the Abort button to stop your VI is like using a tree to stop your car. It works, but there may be consequences.