Without a TKE, I don't think there is any other method.

If you do have a TKE, there is a very nice and very secure method of completely 
cloning everything from one crypto card to another one.  This was added a 
couple of releases ago.  Here is the beginning of the description from the 
current TKE user's guide (which I just retrieved from Resource Link):

-------------------------------
Configuration migration

The TKE workstation provides tools to securely capture host crypto module
configuration data to a file, and then reapply this data to another host crypto
module or crypto module group. The data that can be securely captured includes
roles, authorities, domain control settings, and master keys. These tools 
simplify
the task of installing new or replacement host crypto modules, and can be used 
for
backup and disaster recovery as well.

Two tools are provided: one that migrates only public configuration data (roles,
authorities, domain control settings) and one that migrates all configuration 
data,
including secret data, such as master key values. The protocol for migrating 
secret
data is more complex than the protocol for migrating only public data, and
requires the participation of several smart card holders.
-------------------------------

Todd Arnold

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